modern materials handling - october 2010

53
® Del Monte Foods: Best in class Page 18 SPECIAL REPORT Top 20 ADC suppliers 26 INFORMATION MANAGEMENT Data capture and mobile computing 30 EQUIPMENT REPORT Carousels improve picking 34 Keith Arntson, vice president of distribution operations, Del Monte Foods mmh.com PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION, WAREHOUSING AND MANUFACTURING October 2010 WEBCAST: Results of the 2010 Pallet Usage and Trending Study Thursday, October 28 @ 2:00 p.m. ET Register: www.mmh.com/palletsurvey

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Page 1: Modern Materials Handling - October 2010

reg

Del Monte Foods

Best in class Page 18

SPECIAL REPORT

Top 20 ADC suppliers 26INFORMATION MANAGEMENT

Data capture and mobile computing 30EQUIPMENT REPORT

Carousels improve picking 34

Keith Arntson vice president of distribution operations Del Monte Foods

reg

m m h c o m

PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION WAREHOUSING AND MANUFACTURING

October 2010

WEBCAST

Results of the 2010 Pallet Usage and Trending StudyThursday October 28 200 pm ETRegister wwwmmhcompalletsurvey

MMH1010Covindd 1 101310 300 PM

CLICK HERE for our ldquoWorkstation Integration System Evaluation White Paperrdquo

MM1005 ppxx Dehncoindd 1 51410 903 AM

+ = Synergy pure and simple

MMH1010_Adsindd 2 101210 1056 AM

Dematic Group a leading global supplier of integrated materials handling solu-tions and services has successfully completed the acquisition of HK Systems a North american automated materials handling and soft-ware solutions provider this strategic union was made final on Sept 15 2010

John K Baysore ceo of Dematic North america (wwwdematicus) will be responsible for leading and developing the newly combined company in the united States and canada With more

than 20 years of executive experience Baysore will lead Dematic in the design delivery and support of a more robust and diversified solution offering to the companyrsquos customers the newly combined company will be called Dematic with its North american headquarters in Grand rapids mich the expanded manufacturing foot-

print will allow Dematic to domestically manufacture automated storage and retrieval machines and automated guided vehicles in addition to conveyor sortation and order fulfillment technology

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 3

Lift trucK DiStriButor Barclay Brand ferdon is supporting National Breast cancer awareness month by raising money and awareness the distributor is displaying a pink painted Yale lift truck on its front lawn through the month of october and they plan to participate in the american cancer Societyrsquos ldquomaking Strides against Breast cancerrdquo walk in Woodbridge center (Woodbridge NJ) on oct 17

ldquoWe have pledged to match all of the donations made by our employeesrdquo said Skip russo president and ceo of Barclay Brand ferdon ldquoi am proud of the people

who work for Barclay although it has been a tough economy for all of us our employees have really stepped up to make a difference in our community Wersquove also had a great response from our vendors in support of this effortrdquo Barclay Brand ferdon is a distributor in New Jersey and New York for all warehousing equipment and support services

Pink lift truck supports breast cancer awareness month

1913the number of exhibiting companies at PaCK eXPo international oct 31 to Nov 3 at mccormick place in chicago

dematic group completes acquisition of HK systems

new player in the carousel market

FAST FACT

UP FRONT B r e a k i n g n e w s y o u s h o u l d k n o w

CeMa report says booked orders were down in July

a NeW proviDer Sapient automation is entering the market for vertical and horizontal carousels and vertical lift modules (vLms) according to ed romaine chief marketing officer for Sapient (wwwgetsapientcom) romaine announced the formation of the new company

at the fall meeting of the material Handling industry of america (mHia) in palm Springs calif the new com-pany is a subsidiary of mDci a pro-vider of industrial automation solu-

tions to the uS postal Service ldquoWe launched the company in Januaryrdquo romaine said ldquoand wersquove spent the last nine months ramping uprdquo While the company is a new player

romaine said Sapient has completed its first sale to an industrial facility in the healthcare industry

iN itS LateSt moNtHLY report the conveyor equipment manufacturers association (cema wwwcemanetorg) reported its July 2010 Booked orders index was 131 the index in July is down 36 points or 22 from June 2010rsquos index of 167 While down from June the July 2010 index represents an increase of 49 from the July 2009 index of 88

What does this mean Bob reinfried cemarsquos executive vice president said the conveyor industry had a very good month While down from June July 2010 was still better than July 2009 itrsquos too early to tell if numbers will continue to climb cema is forecasting an increase of 2 to 3 for the North american conveyor market in 2010

Baysore

MMH1010_Upfrontindd 3 101210 158 PM

wwwhyundai-cecom

Beyond the LimitsHyundairsquos cutting-edge technology is the new criteria of

forklift trucks

HEAD OFFICE(REP of KOREA) Tel 82 2 746 4526 Fax 82 2 746 7444~5 E-mail jcjunghhicokr wwwhyundai-cecom

HCE AMERICAS(USA) Tel 1 847 437 3333 Fax 1 847 437 3574 wwwhceamericascom HHI EUROPE(BELGIUM) Tel 32 14 56 2200 Fax 32 14 59 3405~6 wwwhyundaieu HHI BEIJING(CHINA) Tel 86 10 8321 3377 Fax 86 10 5143 8502 wwwhyundai-bjcom

DUBAI BRANCH OFFICE(UAE) Tel 971 4 425 7995 Fax 971 4 425 7996 E-mail sbyunhhicokr

ISTANBUL BRANCH OFFICE(TURKEY) Tel 90 212 345 1261~2 Fax 90 212 345 1263 E-mail eunsoohhicokr

MOSCOW BRANCH OFFICE(RUSSIA) Tel 7 495 258 1381 Fax 7 495 258 1382 E-mail leokanghhicokr

FORKLIFT LINE-UP

LPG Forklift 15 - 45Ton Battery Forklift (Counter Balanced) 16 - 5Ton

Reach Truck (Seated) 14 - 25TonReach Truck (Standing) 1 - 25Ton Electric Towing Platform Truck40TA-715PA-7

Diesel Forklift 15 - 18Ton

MMH1010_Adsindd 4 101210 1053 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 5

PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION WAREHOUSING AND MANUFACTURING

VOL 65 NO 10

DEPARTMENTS amp COLUMNS 3 Upfront 7 This Month in Modern16 Lift Truck Tips Level the playing field38 Focus On Palletizers42 Supplement WarehousesDCs50 60 seconds with

NEWS 9 MHIA Growth is back 9 HighJump to acquire TrueCommerce10 Final thoughts on Supply Chain Reset13 Industrial real estate market making

progress challenges remain

14 Crown unveils 20 electric lift trucks to operate with fuel cells

COVER STORYSYSTEM REPORT

18 Best in classDel Monte Foodsrsquo new Topeka DC brings laser-guided AGVs from manufacturing into distribution The result is a best-in-class materials handling system that minimizes costs with room to expand in the future

22 Automatic guided vehicles streamline operationsLaser-guided AGVs move product from the manufacturing plant and through the distribution center

FEATURESPRODUCTIVITY SOLUTION

25 Tilt toward safety and productivityAluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

SPECIAL REPORT

26 Top 20 automatic data capture suppliersThe ADC market took a significant hit in 2009 but the recovery may already be underway

INFORMATION MANAGEMENT

30 In sync Data capture and mobile computing Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

EQUIPMENT REPORT

34 Carousels Turning picking into productivityNot just for high-density storage anymore todayrsquos carousels are delivering product to the person while increasing productivity reducing labor saving space and cutting energy costs

60 seconds with Joan Barrett Kellogg p 50

Modern Materials Handling reg (ISSN 0026-8038) is published monthly by Peerless Media LLC a Division of EH Publishing Inc 111 Speen St Suite 200 Framingham MA 01701 Annual subscription rates for non-qualifi ed subscribers USA $119 Canada $159 Other International $249 Single copies are available for $2000 Send all subscription inquiries to Modern Materials Handling 111 Speen Street Suite 200 Framingham MA 01701 USA Periodicals postage paid at Framingham MA and additional mailing offi ces POSTMASTER Send address changes to Modern Materials Handling PO Box 1496 Framingham MA 01701-1496 Reproduction of this magazine in whole or part without written permis-sion of the publisher is prohibited All rights reserved (C)2010 Peerless Media LLC

reg

PHOTO BLAINE FISHERGETTY IMAGES

Keith Arntson and his team at Del Monte put a fl eet of laser-guided AGVs to work at their DC

handling system that minimizes costs with room to expand in the future

60 seconds with Joan Barrett Kellogg p 50

BLAINE FISHERGETTY IMAGES

MMH1010_TOCindd 5 101310 947 AM

Introducing the new Automatic Destratification System

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Bottom line you could save up to 30 on your heating bills this winterhellip and next winterhellip and next winterhellip

pending Automatic Destratification System keeps your space

Bottom line you could save up to 30 on your heating bills

NEWNEWNEW

Visit wwwBigAssFanscom or call 877-BIG FANS (877-244-3267) to learn moreAn ISO 90012008 certified company

If global warming doesnrsquot reduce your energy costs this winter perhaps we can help

Covered by one or more of the following US Patents 6244821 6589016 6817835 6939108 7252478 7284960 7654798 D587799 D607988 and other patents pending

10 year parts 1 year labor warranty certain exclusions apply See complete warranty for details copy 2010 Delta T Corporation dba The Big Ass Fan Company All rights reserved

BAF_MMH_DestratAd_091610indd 1 91710 851 AMMMH1010_Adsindd 6 101210 1053 AM

EDITORIAL OFFICES111 Speen Street Suite 200Framingham MA 01701-1496(800) 375-8015

Michael LevansGROUP EDITORIAL DIRECTOR mlevansehpubcom

Bob TrebilcockEXECUTIVE EDITOR

roberttrebilcockmyfairpointnet

Noeumll P BodenburgEXECUTIVE MANAGING EDITOR

nbodenburgehpubcom

Lorie King RogersASSOCIATE EDITOR

lrogersehpubcom

Sara Pearson SpecterEDITOR AT LARGE

saramoxiemarketingllccom

Roberto MichelEDITOR AT LARGE

robertomichelnewrrcom

Tom AndelCOLUMNIST

tandel4315aolcom

Jeff BermanGROUP NEWS EDITOR

jbermanehpubcom

Josh BondCONTRIBUTING EDITOR

turbobondgmailcom

Mike RoachCREATIVE DIRECTOR

mroachehpubcom

Wendy DelCampoART DIRECTOR

wdelcampoehpubcom

Daniel GuideraILLUSTRATION

danieldanielguideracom

Brian CeraoloGROUP PUBLISHER bceraoloehpubcom

EDITORIAL ADVISORY BOARD

Ron Giuntini OEM PRODUCT-SERVICES INSTITUTE

John HillESYNC

TRANSYSTEMS

Susan RiderRIDER amp ASSOCIATES

Ken RuehrdanzDEMATIC

Dr John Usher UNIVERSITY OF LOUISVILLE

Col Alan B Will2D MARINE LOGISTICS GROUP

Brett WoodTOYOTA MATERIAL HANDLING USA

Peerless Media LLCA DIVISION OF EH PUBLISHING INC

Kenneth MoyesPRESIDENT AND CEOEH PUBLISHING INC

Brian CeraoloPUBLISHER AND EXECUTIVE VICE PRESIDENT

PEERLESS MEDIA LLC

MAGAZINE SUBSCRIPTIONSStart renew or update your FREE magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPhone 1-800-315-1578Mail Peerless Media PO Box 1496 Framingham MA 01701

eNEWSLETTER SUBSCRIPTIONSSign up or manage your FREE eNewsletter subscriptions at wwwmmhcomenewsletters

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 7

reg

Member Member ofOfficial Publication of

Winner Jesse H Neal

Certificates of Merit for Journalistic

Excellence

EDITORIAL OFFICES111 Speen Street Suite 200Framingham MA 01701-1496(800) 375-8015

Michael LevansGROUP EDITORIAL DIRECTOR mlevansehpubcom

Bob TrebilcockEXECUTIVE EDITOR

roberttrebilcockmyfairpointnet

Noeumll P BodenburgEXECUTIVE MANAGING EDITOR

nbodenburgehpubcom

Lorie King RogersASSOCIATE EDITOR

lrogersehpubcom

Jeff BermanGROUP NEWS EDITOR

jbermanehpubcom

Sara Pearson SpecterEDITOR AT LARGE

saramoxiemarketingllccom

Roberto MichelEDITOR AT LARGE

robertomichelnewrrcom

Josh BondCONTRIBUTING EDITOR

turbobondgmailcom

Mike RoachCREATIVE DIRECTOR

mroachehpubcom

Wendy DelCampoART DIRECTOR

wdelcampoehpubcom

Daniel GuideraILLUSTRATION

danieldanielguideracom

Brian CeraoloGROUP PUBLISHER bceraoloehpubcom

EDITORIAL ADVISORY BOARD

Ron Giuntini OEM PRODUCT-SERVICES INSTITUTE

John HillESYNC

TRANSYSTEMS

Susan RiderRIDER amp ASSOCIATES

Ken RuehrdanzDEMATIC

Dr John Usher UNIVERSITY OF LOUISVILLE

Col Alan B Will2D MARINE LOGISTICS GROUP

Brett WoodTOYOTA MATERIAL HANDLING USA

Peerless Media LLCA DIVISION OF EH PUBLISHING INC

Kenneth MoyesPRESIDENT AND CEOEH PUBLISHING INC

Brian CeraoloPUBLISHER AND EXECUTIVE VICE PRESIDENT

PEERLESS MEDIA LLC

MAGAZINE SUBSCRIPTIONSStart renew or update your FREE magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPhone 1-800-315-1578Mail Peerless Media PO Box 1496 Framingham MA 01701

eNEWSLETTER SUBSCRIPTIONSSign up or manage your FREE eNewsletter subscriptions at wwwmmhcomenewsletters

MICHAEL LEVANSGROUP EDITORIAL

DIRECTOR

THIS MONTH IN MODERN

While it may be at a much slower pace than predicted growth is actually taking place whether

yoursquore feeling it or not In fact we kick off this monthrsquos issue with the latest report from the Material Handling Industry of America that forecasts equipment orders to grow 12 to 14 in 2010 if the current momen-tum persists (page 9)

Mind you those new numbers are com-ing off 2009 when orders saw a 343 de-cline from 2008 But any way we position the latest forecast we canrsquot help but see it as positive news for the industry overall It may even help to crack a few smiles

But while numbers donrsquot lie they can of-ten be deceiving Even though it appeared that equipment orders fell off a cliff two years ago that didnrsquot mean that materials handling professionals went into hiberna-tion in terms of executing improvement projects

In his thoughtful wrap up of HK Systemsrsquos recent Material Handling and Logistics Con-ference (page 10) executive editor Bob Tre-bilcock recounts a number of conversations that he had with attendees who were eager to share the details of the projects that they completed over the past 18 months or moved to the front burner over the past six months There was a local authority looking to put in a new ASRS the Federal Reserve Bank was investigating storage systems and even a specialty foods manufacturer looking to expand a fl eet of AGVs

ldquoI donrsquot think companies plan multi-million dollar investments in automation if

they think the apocalypse is right around the cornerrdquo observes Trebilcock

My fi rm belief that innovation never goes out of stylemdashno matter what the economic environment may bemdashhas been further validated in the system reports that have graced Modernrsquos covers over the past two years Offi ce Depot Kroger Crate amp Barrel Patagonia Bon-Ton Stores The Ap-parel Group IKEAhellipand the list goes on Each of these innovation mavericks has put precious time and strategic thought into materials handling projects that will put them in a distinct competitive advantage as the economic fog begins to clear

Itrsquos safe to say that the brutal economy never once stopped Keith Arntson vice president of distribution operations for Del Monte Foods from thinking how to he could help take miles out of the food giantrsquos distribution network by applying a few new innovations inside his To-peka Kan DC In fact after reading this monthrsquos System Report (page 18) you can say that Arntson has fl ipped over a few materials handling axioms en route to a stunning success

This month Irsquom going to leave Modern readers with a challenge After reading the Del Monte success story Irsquod like you to share with us a few of the innovation projects that yoursquove conducted during the past 18 months We believe that innovation never goes out of style now help us spread the good word and inspire a few of the late adopters Please send me an email on your better idea(s) mlevansehpubcom

Innovation never goes out of style

MMH1010_Editorialindd 7 101310 254 PM

Modern Materials Logistics Management Supply Chain Management

bull Automation

bull Conveyors amp Sorters

bull Inventory amp Picking

bull Loading Dock Equipment

bull Mobile amp Wireless

bull Shipping Pallets

bull Storage Systems

bull Containers amp Totes

bull Energy amp Sustainability

bull Lift Truck amp Fork Lift

bull Handling amp Warehouse Ergonomics

bull Packaging

bull Software amp Technology

wwwmmhcomcriticaltopics

Critical Industry News at Your Fingertips

Critical Topic areas help you develop strategies and expand your knowledge Each topic provides you with the news information and resources you need mdash each day

CRITICAL TOPICS

Modern Materials Logistics Management Supply Chain Management

MMH_CriticalTopics_Houseindd 1 81010 117 PMMMH1010_Adsindd 8 101210 1053 AM

ITrsquoS STILL A FAR CRY FROM 2007 but the materials handling industry is growing once again Following a 343 decline in equipment orders in 2009 the Material Handling Industry of America (MHIA wwwmhiaorg) is forecasting equipment orders to grow 12 to 14 in 2010 if the current momentum continues

A variety of factors are driving growth in manufacturing warehous-ing and distribution on a global basis especially an increase in industrial pro-duction in the fi rst half of 2010 despite factory utilization rates that remain very low by historical comparison

ldquoConsumer demand has not returnedrdquo Hal Vandiver executive vice president of business develop-ment for MHIA told Modern during the associationrsquos fall meeting ldquoBut in the fi rst two quarters the economy shifted from recession into recovery mode fi lling supply chain pipelines re-establishing inventories and re-sponding to pent up demandrdquo

While Vandiver expects the indus-try to continue to grow by 11 to 12 in 2011 drags on the economy continue ldquoForecasts are now calling for a combination of reduced GDP corporate profi t business investment and output growth with industrial utilization remaining below 75 until

late 2011rdquo Vandiver said ldquoThis is largely due to uncertainty Consumers inves-tors and business owners need greater confi dence in the economyrsquos ability to sustain positive growthrdquo For those reasons Vandiver doesnrsquot expect a signifi cant return to the kinds of num-bers the industry posted in the past up until 2007

In addition to

a growth in orders for new equipment Van-diver forecasts material handling shipments to grow 3 to 4 in 2010 and another 10 to 11 in 2011 Domestic demand defi ned as shipments plus imports less exports will grow by 1 in 2010 and by 10 to 11 in 2011 Exports will be stronger than im-ports in 2010 and 2011 refl ecting stronger indus-trial growth in emerging markets outside North America

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 9

Company Briefi ngs | Bob Trebilcock

The age of automationExpressed as an equation The industrial age + the information age = the automation age

mmhcomblogsautomation

Diblogbest of Modernrsquos blogs

BY BOB TREBILCOCK EXECUTIVE EDITOR

ECONOMY

MHIA Growth is backMHIA FORECASTS 12 TO 14 GROWTH IN NEW EQUIPMENT ORDERS IN 2010

0

-343

2009 2010

130(forecast)

MHIA equipment orders forecast

Source Material Handling Industry of America (MHIA)

HIGHJUMP SOFTWARE announced today that it has reached agreement to acquire TrueCommerce a provider of business-to-business integration solutions TrueCommerce provides a comprehensive end-to-end suite of trading partner connectivity solutions including electronic data interchange (EDI) translation and data mapping software transaction network and on-boarding services HighJump Software (wwwhighjumpcom) ranks

No 11 on Modernrsquos 2010 Supply Chain Management Software an-nual list with $85 million in revenue TrueCommercersquos solutions enable trading partner connectivity for 3000 customers feature predefi ned inte-gration to many major ERP systems and can be deployed in either SaaS or on-premise models

The TrueCommerce trading part-ner integration solution complements HighJump Softwarersquos existing supply

MampA

HighJump to acquire TrueCommerce

mmh1010_newsindd 9 101310 1049 AM

middot Robotic palletizing cells handle goods at the end of the production linemiddot LGVs transport pallets to stretch wrapping and labelingmiddot LGVs transport finished pallets to the warehousemiddot LGVs for Storage amp Retrieval (SRS)middot LGVs for Auto-Trailer Loading (ATL)middot An integrated software management system

Elettric 80 is a global provider of end-of-lineautomation solutions These solutions are called Freewayreg material handling system

The technologies are adaptable and have a high degree of built-in flexibility which makes them suitable for any plant warehouse layout or design More details explanatory videos and animations can be found at wwwelettric80com

ITALY middot USA middot SWEDEN middot UK middot AUSTRALIA middot POLAND

Elettric 80 Inc8100 Monticello AvenueSkokie IL 60076 USAPhone +1 847 329 7717e80usaelettric80it

Freewayreg is based on a simple idea

C

M

Y

CM

MY

CY

CMY

K

el80_US_verticalpdf 1 2010-09-29 1346

chain application suite which spans from supplier to store shelf and includes warehouse management systems transportation management systems route accounting systems manufacturing execution mobile sales and ERP data collection Trading partner collaboration is increas-ingly important as organizations strive to reduce costs and improve service levels By combining integration solutions with application functionality organizations are able to ensure consistency in business processes and accuracy of information exchanged with trading partners

ldquoTrueCommerce has fi lled a unique need in the market for simple robust and affordable EDI solutions for small and midsized businessesrdquo said Nick Manolis TrueCom-merce CEO ldquoI am excited for the TrueCommerce team to join HighJump while continuing to provide excellent service support and product innovation to our customersrdquo

ldquoCombining HighJump and TrueCommerce creates a unique and compelling solution offering within the supply chain software marketrdquo said Russell Fleischer HighJump Software CEO ldquoOur view is that supply chain applications must allow users to connect with a broad ecosystem of trading partners to maximize value The TrueCommerce solution platform and our previous move to cloud-based applications will help translate this vision into reality for our customersrdquo

SUPPLY CHAIN NEWS ANALYSIS

Final thoughts on Supply Chain Reset conferenceBY BOB TREBILCOCK EXECUTIVE EDITOR

DESPITE SIGNS OF IMPROVEMENTS doing business in in materials handling remains a challenge At the same time many of the leading customers are investing in supply chain software and automated materials handling systems to improve their businesses That suggests better times are coming

Tom Brokaw punctuates the 25th anniversary of the Material

Handling and Logistics Conference by HK Systems

mmh1010_newsindd 10 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 11

Leader of the PackThe originator of high speed narrow belt sortationTGW Systems has led the way in offering provenadvantages over conventional sortation for over 10 years

NBS fromTGW Systems

50 less install time60 less energy75 less noise

100 of the Value

wwwtgw-groupcom

TGW Systems (formerly TGW-Ermanco) is an integrated logistics solutions and material handling equipment provider The Ermanco name lives onas the product family name for the conveying andsortation products manufactured in the US

Our worldwide perspective and resources and commitment to innovation product developmentand unparalleled customer service can help you today

Proven track record ndash Over 700 installations around the world have made TGWrsquos Narrow Belt Sorter one of the most reliable sorters available

Rugged durability ndash TGWrsquos NBS sorters operate in some of the harshest distribution environments in the world earning customerrsquos admiration and competitorrsquos respect

Application and layout fl exibility ndash The universal frame on TGWrsquos narrow belt sorter means you can use multiple divert options and easily add divert modules after installation for increased fl exibility

Patented technology ndash Patented sortation technology in the TGWrsquos narrow belt sorter continues to lead the way in effective energy effi cient fl exible sortation

10 08 NBSindd 1 8302010 34008 PM

keep enough labor to run his primary distribution center Two presentations drove this point home The fi rst was from an executive with Tim Hor-tons the Dunkin Donuts of Canada The companyrsquos beautiful new DC in Guelph Ontario is underperforming projections even though the ASRS is

living up to its promises The reason The company canrsquot fi nd enough labor willing to work in its case picking and palletizing operations The other was by Terra Winston a consultant who presented a case study about a proj-ect at PepsiCo to develop the next wave of supply chain leaders Her

Those are the two high level take-aways from Supply Chain Reset the annual logistics conference held last month in Park City Utah sponsored by HK Systems now part of Dematic

ldquoLousyrdquo was the most common response to the dinner-time question ldquoHowrsquos businessrdquo

At the same time the roll call of end user companies that said they had projects in the works or on the drawing board was both a Whorsquos Who of American business with names like Coca-Cola and Kraft and companies many of us may never have heard of or think of as custom-ers of our solutions For example I sat on the van from the airport with a guy from the Los Angeles metro-politan transportation system looking for a new automated storage and retrieval system (ASRS) The Federal Reserve Bank was there investigat-ing storage systems I rode in the van back to the airport with a woman from a producer of honey in Texas who had both an ASRS and auto-matic guided vehicles in her facil-ity and was looking to expand her system

Those are signs of a growing con-fi dence I donrsquot think companies plan multi-million dollar investments in au-tomation if they think the apocalypse is right around the corner

One other anecdotal data point Marc Ducharme a vice president and partner with Axium a supplier of robotic materials handling solu-tions told me that 2009 was a dismal year for implementations but that his company has been swamped with RFPs in 2010 An RFP is not an order but itrsquos a sign

A few other observationsRetaining labor and talent could

be the most important issue facing the industry in the future A week or so before going to Utah I had a con-versation with a vice president of sup-ply chain for a major retailer who told me he is interested in automation because he simply cannot fi nd and

mmh1010_newsindd 11 101310 1049 AM

12 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

point the talent shortage isnrsquot limited just to the shop fl oor

Retrofi tting is a viable solution You know the old saying Every-thing old is new again Wegmanrsquos a Midwestern grocer and Rubber-maid both gave strong presenta-tions about how they replaced ag-ing ASRS cranes to breathe new life into their DCs Meanwhile Anheuser Busch gained new ef-fi ciencies in its Columbus Ohio facility by upgrading a warehouse control system

Everyone loves pallets Based in Iowa Green Line Armor is offering a heavy-duty hybrid woodplastic pallet for permanent pallet pools The 48- x 40-inch pallet has heavier stringers and more deck board coverage than a grocery pallet The lead boards on the top and the bottom of the palletmdashthose most likely to get damaged by a lift truckmdashare manufactured from heavy plastic The pallet has a passive RFID

tag that is used by Green Line Armor to identify the pallet and manage war-ranty services Active RFID tags were installed for John Deere the companyrsquos largest customer to track the location of work in process stored on the pallets between manufacturing processes Eric Renteria the companyrsquos president said the pallets which come with a 10-year warranty can be purchased or leased

in a pooling modelNew players are get-

ting into automation Kip Tygard whose company makes the Tygard Claw a lift truck attachment for mixed case palletizing is investing RampD money to develop an automated version of the Claw Thatrsquos not a big shock Tygard is an OEM But I also had conversations with two very large end users in the wholesale food distribu-

tion business that have designed their own automated systemsmdashone has built and implemented its own ASRS design for freezers for years the other has designed its own case picking application that it intends to put out for bid to the materials handling community Both say they may commercialize their solutions in the future

VERSATILITY MATTERSQuality Wildeck construction and versatility make the V-lifttrade the ultimate lifting solution

In todayrsquos lsquogreenrsquo building designs floor space is at a premium and moving up not out is definitely preferred Look no further than the V-Lifttrade from Wildeck ndash the industry leader in space optimization The single cylinder hydraulic system eliminates all moving hoses cables and chains Fewer components means easy installation reduced maintenance and longer service life To get more value out of your operation contact a Wildeck representative today

copyWildeck Inc 2010 Required safety gates and guarding removed for clarity

800-325-6939 | WWWWILDECKCOM

MEZZANINESCapacity Matters Efficiency Matters

LIFT SYSTEMSSafety MattersGUARDING PRODUCTS

able to make better decisionsmdashespecially in the case of the unexpected ldquoWhen a shipment is held up at the portrdquo says Prashant Bhatia director of solutions management at SAP ldquoit can trigger logic back to say that Irsquove got a problem I can no longer allocate that inventory on that particular shipment as I thought I couldrdquo

3 One database one system one supply chain In the last few years soft-ware providers have been pulling all of their products onto a single supply chain process platform ldquoItrsquos fairly newrdquo says Lamphier ldquoVarious components have been integrated into that supply chain process platform longer than others but actually moving our WMS onto it has been a more recent developmentmdashjust within the last quarter or twordquo

SAP uses its enterprise resource planning (ERP) system as the central repository of information of supply and demand as well as inventory for the entire supply chain And the modules all

talk to each other Transportation man-agement systems (TMS) in conjunction with the event management modules help optimize freight determine pick-up windows determine carriers keep track of in-transit times and create ASNs

That ASN not only gets sent back to the ERP for visibility but it also gets sent to the WMS where the sys-tem uses the information to plan labor equipment and resources at the receiv-ing dock When the physical product arrives logic within the WMS based on the receipt of goods determines matches against actual demand

Smarter speedier equipment With more retailers crossdocking

over 50 of their items at the case level to their stores equipment innovations have centered on conveyor sortation systems print and apply mechanisms and automatic identifi cation technolo-gies Here are three new equipment

advances1 Smaller gaps and self-regulat-

ing conveyors In the last year the sliding shoe sorter has undergone note-worthy transformations ldquoBy doing a par-allel divert we can now run the packages closer together and get a higher through-put on the same systemrdquo reports Ken Ruehrdanz manager for Dematicrsquos distri-bution and warehousing markets

The sliding shoes that used to physi-cally push the cartons off the sorter at an angle can now run those shoes in parallel enabling smaller gaps between cartonsmdashwhich were previously from 6 inches to 8 inchesmdashdown to 3 inches

With more dense traffi c on conveyors crossdock operators can run their con-veyors at a lower speed while still achiev-ing the same throughput Slower speeds equal less wear and tear decreased energy usage and less maintenance

Another conveyor breakthrough is automatic speed control ldquoThe whole

m m h c o m MODERN MATERIALS HANDLING A P R I L 2 0 1 0 49S

MMH100401sup_Crossdock_ID 49 482010 113620 AM

Leading customers are investing in software and automated

systems to improve business according to attendees of the

Supply Chain Reset conference

mmh1010_newsindd 12 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 13

THE INDUSTRIAL REAL ESTATEmarket is taking steps in the right direction according to a report recently issued by global real estate fi rm Jones Lang LaSalle (JLL wwwjoneslanglasallecom) which report-ed the national average vacancy rate for the North American industrial real estate sector fell from 106 in the fi rst quarter to 104 in the second quarter Despite the slight decline in vacancy the fragile economy still looms large due to declining con-sumer confi dence the drying up of economic stimulus funding and the potential threat of a double-dip recession the report noted

ldquoWe have seen a positive absorp-tion in the vacancy rate in the second quarter but we are very concerned

going forwardrdquo Craig Meyer managing director and leader of JLLrsquos Logistics and Industrial Services Group told Modern ldquoAny kind of sustained demand-driven component in the industrial real estate market is going to be driven by jobs We are just not seeing any of that It is going to be a long slow recoveryrdquo

Looking at base indicators like the Institute of Supply Managementrsquos Manufacturing Index Consumer Confi dence data and industrial real estate vacancy and absorption rates there does not appear to be what Meyer labeled as a strong indication of a positive upswing on the horizon

The report says that a need to restock inventories that were running at 50-year lows resulted in large com-panies strategically capturing high

quality logistics space at cyclically low rates And with slow levels of leasing activity and sparse construc-tion industrial real estate optionsmdashespecially in the Class A large block sectormdashare limited in some markets

And the swift correction in invento-ries during the second half of 2009 and fi rst quarter of 2010 has left inventory levels lean and ready for expansion provided sales rebound in the coming months Should this occur it could lead to increased industrial and logistics real estate leasing activity

The report also pointed out that the initial recovery in the economy was largely driven by improvements in the manufacturing sector and cyclical adjustments in inventories But with the recovery now becoming more broad-based the recent slowdown of inven-tory building could have more of an impact on the industrial property sector than the offi ce sector the report noted

Date 090910 Client Rehrig Pacifi c Job 08312010 File Name 0831_RPC_SlipSheet_Ad_MMH_Oct10 Round

Account Director Niki Phan Designer Revised By ov Editor Production ov

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Publication(s) TBD Run Date(s) TBD

Approved By

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Available in standard or custom sizes with a variety of surface textures and embossed patterns Rehrig Slip Sheets provide superior slide resistance keeping goods securely in place Manufactured from nearly 100 recycled material each sheet is also 100 recyclable

Beyond the sale Rehrig can help you develop a customized re-use or buy-back program further lowering your average cost per trip

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Industrial real estate market making progress challenges remain

mmh1010_newsindd 13 101310 1049 AM

14 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

ldquoWe are also concerned about seasonality with the holiday season coming uprdquo said Meyer ldquoThe indica-tions we are getting are that we may not see as much preparation for that as we hoped A lot of retailers are saying they are restocked and if consumer confi dence is going down they are not going to build up inventories And for larger big box companies they will see declining values in rents but the availability of product for them to lease is diminishingrdquo

As a result Class A big box dis-tribution space is becoming more diffi cult to fi nd in this economy said Meyer But the build-to-suit market could come back for major retailers as evidenced by a new 1-million-square-foot DC space deal by Amazoncom in Harrisburg Pa and a 14-million-square-foot location in Phoenix

But for a mid-sized industrial building in the 100000-to-150000-square-foot range Class B-sized build-

ing Meyer said there are an infi nite number of these on the market

Looking ahead Meyer said there will still be downward pressure on pric-

ing a double-digit vacancy rate and no increases in lease rates which he noted are actually weakening a little bit and tend to lag a recovery

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BFL AD MMH APRIL 92710 358 PM Page 1

CROWN EQUIPMENT Corp has quali-fi ed 20 of its electric models to operate with various fuel cells bringing the total of qualifi ed combinations of fuel cell packs and trucks to 29 In 2009 Crown (wwwcrowncom) was the fi rst lift truck manufacturer to introduce a fuel cell qualifi cation program

Eric Jensen Crownrsquos manager of new technology research and de-velopment told Modern that the companyrsquos fuel cell qualifi cation pro-gram duplicates its own testing and is conducted at a 25000-square-foot research facility near Dayton Ohio Through the testing process engi-

neers evaluate fuel cell performance and monitor whether issues develop that affect the truckrsquos operation

To qualify a fuel cell pack and truck combination Crownrsquos engineers review key performance metrics for a battery-powered truck such as traction plug-ging and lift and travel speeds Then they replace the battery with a fuel cell power pack and measure the same indicators Through modeling and ap-plication testing the research team de-termines design modifi cations needed to ensure the fuel cell-powered forklift matched standards to which the truck was designed

LIFT TRUCKS

Crown unveils 20 electric lift trucks to operate with fuel cells

mmh1010_newsindd 14 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 15

ldquoWersquove been steadfast in our posi-tion that deployment of a fuel cell forklift fl eet must be carefully evalu-ated and tested for appropriate use in a warehouserdquo said Jensen ldquoThis research-based approach means that our customers can confi dently know they have the right truck for their chosen fuel cell allowing them to meet their performance safety and

environmental sus-tainability goalsrdquo

Crown continues to work closely with fuel cell manufactur-ers and customers to qualify trucks as new fuel cell pack models are intro-duced ldquoForklifts are a key early market for fuel cellsrdquo said Lisa Callaghan Jerram senior market analyst for Fuel Cell Today a leading analyst

fi rm providing market-based research on the fuel cell industry ldquoBased on our market research we have found strong growth in this sector in the past three yearsrdquo

Because fuel cell powered electric forklifts give off exhaust in the form of moist warm air IC truck custom-ers are looking to this technology

so they donrsquot have to deal exhaust issues Jensen said Another advan-tage pointed out by Jensen is a fuel cell powered truckrsquos ability to effec-tively operate in a cold environment because they generate their own heat and the power doesnrsquot fall off like a traditional battery

While the upfront hardware cost of fuel cells is more expensive than a traditional battery Jensen pointed out the potential to capture savings in labor battery changes battery rooms and heating and venting With fuel cells he said a facility doesnrsquot need a battery room and all that goes in to running it properly Instead there is an ongoing savings associated to using fl oor space for production or other value-added operations

ldquoFuel cells have always been talked about fi ve years into the future but we have customers who are [currently] planning installations around this prod-uctrdquo said Jensen ldquoThe future is hererdquo

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To qualify a fuel cell pack and truck combination engineers

review key performance metrics

mmh1010_newsindd 15 101310 1049 AM

lift truck TIPS

GraphicCaption

In the right application tuggers and carts can be a fast and efficient solution

Level the playing field

Football season is under-way and fans are hoping for breakout performances

from stars and rookies alike On the gridiron an overpowered player can be a distinct advan-tage In the warehouse how-ever too much power can lead to waste danger and sluggish performance For some corpo-rations this fact has prompted consideration of fork-free envi-ronments where versatile and custom-built carts and tuggers can do the work faster and more efficiently than their big-ger cousins

Disposing of expensive and powerful equipment in favor of carts may seem counter-intuitive but Jill Burrow marketing manager for Topper Industrial says certain warehouses might benefit greatly from the switch For operations requiring multiple trips between the same areas carts can cut travel time sig-nificantly According to Ed Brown president of Topper Industrial a tugger can pull as many as 13 carts In addi-tion says Brown carts and tuggers can be easier to use than many forklifts

ldquoA forklift costs five times as much but a forklift opera-tor also costs five times more than a tugger operatorrdquo says Brown ldquoAnyone can grab a tugger and gordquo

Once a forklift drops off a pallet in many cases a picker must bend to access product or arrange for the pallet to be lifted Carts on the other hand can be configured with swiveling or angled platforms to allow pickers fast and comfortable access to products Worker safety issues tied to forklifts that operate in tight areas such as poor visibility when driving in re-verse and dock mishaps can also be greatly reduced

ldquoCompanies looking at carts are looking at the cost of equipment and the cost of maintenance but theyrsquore also looking at safetyrdquo says Brown

In addition to ergonomics and safety a fork-free zone might help a warehouse reduce product loss and equip-ment damage Carts provide a secure cradle for moving product while some fork-borne loads are prone to top-pling And forklifts often 10 times as heavy as a tugger and cart setup have a way of proving their strength by leaving dings and dents on storage racks and other hap-less stationary objects

With carts and tuggers Brown says most companies see a return on investment within a year In football a first-round draft pick can cost millions over a multi-year contract before he produces the desired results For com-panies not looking to attempt such a Hail Mary tuggers could prove an efficient alternative

Josh Bond is a contributing editor to Modern and can be reached at turbobondgmailcom

16 O c t O b e r 2 0 1 0 Modern Materials Handling m m h c o m

lift truck TIPS

By Josh Bond Contributing Editor

MMH1010_LiftTruckTipsindd 16 101310 942 AM

MM100601Adsindd 3 6310 349 PMMMH1010_Adsindd 17 101210 1053 AM

18 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

Keith arntson vice president of distribution operations for

del Monte Foods

Four conveyor-topped vehicles ferry loads from an adjacent manufacturing plant

MMH1010_SystemRptDelMonteindd 18 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

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Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

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From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

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MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

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46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

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Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

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Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

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  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 2: Modern Materials Handling - October 2010

CLICK HERE for our ldquoWorkstation Integration System Evaluation White Paperrdquo

MM1005 ppxx Dehncoindd 1 51410 903 AM

+ = Synergy pure and simple

MMH1010_Adsindd 2 101210 1056 AM

Dematic Group a leading global supplier of integrated materials handling solu-tions and services has successfully completed the acquisition of HK Systems a North american automated materials handling and soft-ware solutions provider this strategic union was made final on Sept 15 2010

John K Baysore ceo of Dematic North america (wwwdematicus) will be responsible for leading and developing the newly combined company in the united States and canada With more

than 20 years of executive experience Baysore will lead Dematic in the design delivery and support of a more robust and diversified solution offering to the companyrsquos customers the newly combined company will be called Dematic with its North american headquarters in Grand rapids mich the expanded manufacturing foot-

print will allow Dematic to domestically manufacture automated storage and retrieval machines and automated guided vehicles in addition to conveyor sortation and order fulfillment technology

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 3

Lift trucK DiStriButor Barclay Brand ferdon is supporting National Breast cancer awareness month by raising money and awareness the distributor is displaying a pink painted Yale lift truck on its front lawn through the month of october and they plan to participate in the american cancer Societyrsquos ldquomaking Strides against Breast cancerrdquo walk in Woodbridge center (Woodbridge NJ) on oct 17

ldquoWe have pledged to match all of the donations made by our employeesrdquo said Skip russo president and ceo of Barclay Brand ferdon ldquoi am proud of the people

who work for Barclay although it has been a tough economy for all of us our employees have really stepped up to make a difference in our community Wersquove also had a great response from our vendors in support of this effortrdquo Barclay Brand ferdon is a distributor in New Jersey and New York for all warehousing equipment and support services

Pink lift truck supports breast cancer awareness month

1913the number of exhibiting companies at PaCK eXPo international oct 31 to Nov 3 at mccormick place in chicago

dematic group completes acquisition of HK systems

new player in the carousel market

FAST FACT

UP FRONT B r e a k i n g n e w s y o u s h o u l d k n o w

CeMa report says booked orders were down in July

a NeW proviDer Sapient automation is entering the market for vertical and horizontal carousels and vertical lift modules (vLms) according to ed romaine chief marketing officer for Sapient (wwwgetsapientcom) romaine announced the formation of the new company

at the fall meeting of the material Handling industry of america (mHia) in palm Springs calif the new com-pany is a subsidiary of mDci a pro-vider of industrial automation solu-

tions to the uS postal Service ldquoWe launched the company in Januaryrdquo romaine said ldquoand wersquove spent the last nine months ramping uprdquo While the company is a new player

romaine said Sapient has completed its first sale to an industrial facility in the healthcare industry

iN itS LateSt moNtHLY report the conveyor equipment manufacturers association (cema wwwcemanetorg) reported its July 2010 Booked orders index was 131 the index in July is down 36 points or 22 from June 2010rsquos index of 167 While down from June the July 2010 index represents an increase of 49 from the July 2009 index of 88

What does this mean Bob reinfried cemarsquos executive vice president said the conveyor industry had a very good month While down from June July 2010 was still better than July 2009 itrsquos too early to tell if numbers will continue to climb cema is forecasting an increase of 2 to 3 for the North american conveyor market in 2010

Baysore

MMH1010_Upfrontindd 3 101210 158 PM

wwwhyundai-cecom

Beyond the LimitsHyundairsquos cutting-edge technology is the new criteria of

forklift trucks

HEAD OFFICE(REP of KOREA) Tel 82 2 746 4526 Fax 82 2 746 7444~5 E-mail jcjunghhicokr wwwhyundai-cecom

HCE AMERICAS(USA) Tel 1 847 437 3333 Fax 1 847 437 3574 wwwhceamericascom HHI EUROPE(BELGIUM) Tel 32 14 56 2200 Fax 32 14 59 3405~6 wwwhyundaieu HHI BEIJING(CHINA) Tel 86 10 8321 3377 Fax 86 10 5143 8502 wwwhyundai-bjcom

DUBAI BRANCH OFFICE(UAE) Tel 971 4 425 7995 Fax 971 4 425 7996 E-mail sbyunhhicokr

ISTANBUL BRANCH OFFICE(TURKEY) Tel 90 212 345 1261~2 Fax 90 212 345 1263 E-mail eunsoohhicokr

MOSCOW BRANCH OFFICE(RUSSIA) Tel 7 495 258 1381 Fax 7 495 258 1382 E-mail leokanghhicokr

FORKLIFT LINE-UP

LPG Forklift 15 - 45Ton Battery Forklift (Counter Balanced) 16 - 5Ton

Reach Truck (Seated) 14 - 25TonReach Truck (Standing) 1 - 25Ton Electric Towing Platform Truck40TA-715PA-7

Diesel Forklift 15 - 18Ton

MMH1010_Adsindd 4 101210 1053 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 5

PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION WAREHOUSING AND MANUFACTURING

VOL 65 NO 10

DEPARTMENTS amp COLUMNS 3 Upfront 7 This Month in Modern16 Lift Truck Tips Level the playing field38 Focus On Palletizers42 Supplement WarehousesDCs50 60 seconds with

NEWS 9 MHIA Growth is back 9 HighJump to acquire TrueCommerce10 Final thoughts on Supply Chain Reset13 Industrial real estate market making

progress challenges remain

14 Crown unveils 20 electric lift trucks to operate with fuel cells

COVER STORYSYSTEM REPORT

18 Best in classDel Monte Foodsrsquo new Topeka DC brings laser-guided AGVs from manufacturing into distribution The result is a best-in-class materials handling system that minimizes costs with room to expand in the future

22 Automatic guided vehicles streamline operationsLaser-guided AGVs move product from the manufacturing plant and through the distribution center

FEATURESPRODUCTIVITY SOLUTION

25 Tilt toward safety and productivityAluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

SPECIAL REPORT

26 Top 20 automatic data capture suppliersThe ADC market took a significant hit in 2009 but the recovery may already be underway

INFORMATION MANAGEMENT

30 In sync Data capture and mobile computing Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

EQUIPMENT REPORT

34 Carousels Turning picking into productivityNot just for high-density storage anymore todayrsquos carousels are delivering product to the person while increasing productivity reducing labor saving space and cutting energy costs

60 seconds with Joan Barrett Kellogg p 50

Modern Materials Handling reg (ISSN 0026-8038) is published monthly by Peerless Media LLC a Division of EH Publishing Inc 111 Speen St Suite 200 Framingham MA 01701 Annual subscription rates for non-qualifi ed subscribers USA $119 Canada $159 Other International $249 Single copies are available for $2000 Send all subscription inquiries to Modern Materials Handling 111 Speen Street Suite 200 Framingham MA 01701 USA Periodicals postage paid at Framingham MA and additional mailing offi ces POSTMASTER Send address changes to Modern Materials Handling PO Box 1496 Framingham MA 01701-1496 Reproduction of this magazine in whole or part without written permis-sion of the publisher is prohibited All rights reserved (C)2010 Peerless Media LLC

reg

PHOTO BLAINE FISHERGETTY IMAGES

Keith Arntson and his team at Del Monte put a fl eet of laser-guided AGVs to work at their DC

handling system that minimizes costs with room to expand in the future

60 seconds with Joan Barrett Kellogg p 50

BLAINE FISHERGETTY IMAGES

MMH1010_TOCindd 5 101310 947 AM

Introducing the new Automatic Destratification System

Big Ass Fans have always saved money in the winter but now it can be done with the push of a button The patent pending Automatic Destratification System keeps your space at the perfect temperature year-round from floor to ceiling The Automatic Destratification System calculates the floor-to-ceiling temperature differential and modulates the fanrsquos speed so you donrsquot have to

Bottom line you could save up to 30 on your heating bills this winterhellip and next winterhellip and next winterhellip

pending Automatic Destratification System keeps your space

Bottom line you could save up to 30 on your heating bills

NEWNEWNEW

Visit wwwBigAssFanscom or call 877-BIG FANS (877-244-3267) to learn moreAn ISO 90012008 certified company

If global warming doesnrsquot reduce your energy costs this winter perhaps we can help

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10 year parts 1 year labor warranty certain exclusions apply See complete warranty for details copy 2010 Delta T Corporation dba The Big Ass Fan Company All rights reserved

BAF_MMH_DestratAd_091610indd 1 91710 851 AMMMH1010_Adsindd 6 101210 1053 AM

EDITORIAL OFFICES111 Speen Street Suite 200Framingham MA 01701-1496(800) 375-8015

Michael LevansGROUP EDITORIAL DIRECTOR mlevansehpubcom

Bob TrebilcockEXECUTIVE EDITOR

roberttrebilcockmyfairpointnet

Noeumll P BodenburgEXECUTIVE MANAGING EDITOR

nbodenburgehpubcom

Lorie King RogersASSOCIATE EDITOR

lrogersehpubcom

Sara Pearson SpecterEDITOR AT LARGE

saramoxiemarketingllccom

Roberto MichelEDITOR AT LARGE

robertomichelnewrrcom

Tom AndelCOLUMNIST

tandel4315aolcom

Jeff BermanGROUP NEWS EDITOR

jbermanehpubcom

Josh BondCONTRIBUTING EDITOR

turbobondgmailcom

Mike RoachCREATIVE DIRECTOR

mroachehpubcom

Wendy DelCampoART DIRECTOR

wdelcampoehpubcom

Daniel GuideraILLUSTRATION

danieldanielguideracom

Brian CeraoloGROUP PUBLISHER bceraoloehpubcom

EDITORIAL ADVISORY BOARD

Ron Giuntini OEM PRODUCT-SERVICES INSTITUTE

John HillESYNC

TRANSYSTEMS

Susan RiderRIDER amp ASSOCIATES

Ken RuehrdanzDEMATIC

Dr John Usher UNIVERSITY OF LOUISVILLE

Col Alan B Will2D MARINE LOGISTICS GROUP

Brett WoodTOYOTA MATERIAL HANDLING USA

Peerless Media LLCA DIVISION OF EH PUBLISHING INC

Kenneth MoyesPRESIDENT AND CEOEH PUBLISHING INC

Brian CeraoloPUBLISHER AND EXECUTIVE VICE PRESIDENT

PEERLESS MEDIA LLC

MAGAZINE SUBSCRIPTIONSStart renew or update your FREE magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPhone 1-800-315-1578Mail Peerless Media PO Box 1496 Framingham MA 01701

eNEWSLETTER SUBSCRIPTIONSSign up or manage your FREE eNewsletter subscriptions at wwwmmhcomenewsletters

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 7

reg

Member Member ofOfficial Publication of

Winner Jesse H Neal

Certificates of Merit for Journalistic

Excellence

EDITORIAL OFFICES111 Speen Street Suite 200Framingham MA 01701-1496(800) 375-8015

Michael LevansGROUP EDITORIAL DIRECTOR mlevansehpubcom

Bob TrebilcockEXECUTIVE EDITOR

roberttrebilcockmyfairpointnet

Noeumll P BodenburgEXECUTIVE MANAGING EDITOR

nbodenburgehpubcom

Lorie King RogersASSOCIATE EDITOR

lrogersehpubcom

Jeff BermanGROUP NEWS EDITOR

jbermanehpubcom

Sara Pearson SpecterEDITOR AT LARGE

saramoxiemarketingllccom

Roberto MichelEDITOR AT LARGE

robertomichelnewrrcom

Josh BondCONTRIBUTING EDITOR

turbobondgmailcom

Mike RoachCREATIVE DIRECTOR

mroachehpubcom

Wendy DelCampoART DIRECTOR

wdelcampoehpubcom

Daniel GuideraILLUSTRATION

danieldanielguideracom

Brian CeraoloGROUP PUBLISHER bceraoloehpubcom

EDITORIAL ADVISORY BOARD

Ron Giuntini OEM PRODUCT-SERVICES INSTITUTE

John HillESYNC

TRANSYSTEMS

Susan RiderRIDER amp ASSOCIATES

Ken RuehrdanzDEMATIC

Dr John Usher UNIVERSITY OF LOUISVILLE

Col Alan B Will2D MARINE LOGISTICS GROUP

Brett WoodTOYOTA MATERIAL HANDLING USA

Peerless Media LLCA DIVISION OF EH PUBLISHING INC

Kenneth MoyesPRESIDENT AND CEOEH PUBLISHING INC

Brian CeraoloPUBLISHER AND EXECUTIVE VICE PRESIDENT

PEERLESS MEDIA LLC

MAGAZINE SUBSCRIPTIONSStart renew or update your FREE magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPhone 1-800-315-1578Mail Peerless Media PO Box 1496 Framingham MA 01701

eNEWSLETTER SUBSCRIPTIONSSign up or manage your FREE eNewsletter subscriptions at wwwmmhcomenewsletters

MICHAEL LEVANSGROUP EDITORIAL

DIRECTOR

THIS MONTH IN MODERN

While it may be at a much slower pace than predicted growth is actually taking place whether

yoursquore feeling it or not In fact we kick off this monthrsquos issue with the latest report from the Material Handling Industry of America that forecasts equipment orders to grow 12 to 14 in 2010 if the current momen-tum persists (page 9)

Mind you those new numbers are com-ing off 2009 when orders saw a 343 de-cline from 2008 But any way we position the latest forecast we canrsquot help but see it as positive news for the industry overall It may even help to crack a few smiles

But while numbers donrsquot lie they can of-ten be deceiving Even though it appeared that equipment orders fell off a cliff two years ago that didnrsquot mean that materials handling professionals went into hiberna-tion in terms of executing improvement projects

In his thoughtful wrap up of HK Systemsrsquos recent Material Handling and Logistics Con-ference (page 10) executive editor Bob Tre-bilcock recounts a number of conversations that he had with attendees who were eager to share the details of the projects that they completed over the past 18 months or moved to the front burner over the past six months There was a local authority looking to put in a new ASRS the Federal Reserve Bank was investigating storage systems and even a specialty foods manufacturer looking to expand a fl eet of AGVs

ldquoI donrsquot think companies plan multi-million dollar investments in automation if

they think the apocalypse is right around the cornerrdquo observes Trebilcock

My fi rm belief that innovation never goes out of stylemdashno matter what the economic environment may bemdashhas been further validated in the system reports that have graced Modernrsquos covers over the past two years Offi ce Depot Kroger Crate amp Barrel Patagonia Bon-Ton Stores The Ap-parel Group IKEAhellipand the list goes on Each of these innovation mavericks has put precious time and strategic thought into materials handling projects that will put them in a distinct competitive advantage as the economic fog begins to clear

Itrsquos safe to say that the brutal economy never once stopped Keith Arntson vice president of distribution operations for Del Monte Foods from thinking how to he could help take miles out of the food giantrsquos distribution network by applying a few new innovations inside his To-peka Kan DC In fact after reading this monthrsquos System Report (page 18) you can say that Arntson has fl ipped over a few materials handling axioms en route to a stunning success

This month Irsquom going to leave Modern readers with a challenge After reading the Del Monte success story Irsquod like you to share with us a few of the innovation projects that yoursquove conducted during the past 18 months We believe that innovation never goes out of style now help us spread the good word and inspire a few of the late adopters Please send me an email on your better idea(s) mlevansehpubcom

Innovation never goes out of style

MMH1010_Editorialindd 7 101310 254 PM

Modern Materials Logistics Management Supply Chain Management

bull Automation

bull Conveyors amp Sorters

bull Inventory amp Picking

bull Loading Dock Equipment

bull Mobile amp Wireless

bull Shipping Pallets

bull Storage Systems

bull Containers amp Totes

bull Energy amp Sustainability

bull Lift Truck amp Fork Lift

bull Handling amp Warehouse Ergonomics

bull Packaging

bull Software amp Technology

wwwmmhcomcriticaltopics

Critical Industry News at Your Fingertips

Critical Topic areas help you develop strategies and expand your knowledge Each topic provides you with the news information and resources you need mdash each day

CRITICAL TOPICS

Modern Materials Logistics Management Supply Chain Management

MMH_CriticalTopics_Houseindd 1 81010 117 PMMMH1010_Adsindd 8 101210 1053 AM

ITrsquoS STILL A FAR CRY FROM 2007 but the materials handling industry is growing once again Following a 343 decline in equipment orders in 2009 the Material Handling Industry of America (MHIA wwwmhiaorg) is forecasting equipment orders to grow 12 to 14 in 2010 if the current momentum continues

A variety of factors are driving growth in manufacturing warehous-ing and distribution on a global basis especially an increase in industrial pro-duction in the fi rst half of 2010 despite factory utilization rates that remain very low by historical comparison

ldquoConsumer demand has not returnedrdquo Hal Vandiver executive vice president of business develop-ment for MHIA told Modern during the associationrsquos fall meeting ldquoBut in the fi rst two quarters the economy shifted from recession into recovery mode fi lling supply chain pipelines re-establishing inventories and re-sponding to pent up demandrdquo

While Vandiver expects the indus-try to continue to grow by 11 to 12 in 2011 drags on the economy continue ldquoForecasts are now calling for a combination of reduced GDP corporate profi t business investment and output growth with industrial utilization remaining below 75 until

late 2011rdquo Vandiver said ldquoThis is largely due to uncertainty Consumers inves-tors and business owners need greater confi dence in the economyrsquos ability to sustain positive growthrdquo For those reasons Vandiver doesnrsquot expect a signifi cant return to the kinds of num-bers the industry posted in the past up until 2007

In addition to

a growth in orders for new equipment Van-diver forecasts material handling shipments to grow 3 to 4 in 2010 and another 10 to 11 in 2011 Domestic demand defi ned as shipments plus imports less exports will grow by 1 in 2010 and by 10 to 11 in 2011 Exports will be stronger than im-ports in 2010 and 2011 refl ecting stronger indus-trial growth in emerging markets outside North America

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 9

Company Briefi ngs | Bob Trebilcock

The age of automationExpressed as an equation The industrial age + the information age = the automation age

mmhcomblogsautomation

Diblogbest of Modernrsquos blogs

BY BOB TREBILCOCK EXECUTIVE EDITOR

ECONOMY

MHIA Growth is backMHIA FORECASTS 12 TO 14 GROWTH IN NEW EQUIPMENT ORDERS IN 2010

0

-343

2009 2010

130(forecast)

MHIA equipment orders forecast

Source Material Handling Industry of America (MHIA)

HIGHJUMP SOFTWARE announced today that it has reached agreement to acquire TrueCommerce a provider of business-to-business integration solutions TrueCommerce provides a comprehensive end-to-end suite of trading partner connectivity solutions including electronic data interchange (EDI) translation and data mapping software transaction network and on-boarding services HighJump Software (wwwhighjumpcom) ranks

No 11 on Modernrsquos 2010 Supply Chain Management Software an-nual list with $85 million in revenue TrueCommercersquos solutions enable trading partner connectivity for 3000 customers feature predefi ned inte-gration to many major ERP systems and can be deployed in either SaaS or on-premise models

The TrueCommerce trading part-ner integration solution complements HighJump Softwarersquos existing supply

MampA

HighJump to acquire TrueCommerce

mmh1010_newsindd 9 101310 1049 AM

middot Robotic palletizing cells handle goods at the end of the production linemiddot LGVs transport pallets to stretch wrapping and labelingmiddot LGVs transport finished pallets to the warehousemiddot LGVs for Storage amp Retrieval (SRS)middot LGVs for Auto-Trailer Loading (ATL)middot An integrated software management system

Elettric 80 is a global provider of end-of-lineautomation solutions These solutions are called Freewayreg material handling system

The technologies are adaptable and have a high degree of built-in flexibility which makes them suitable for any plant warehouse layout or design More details explanatory videos and animations can be found at wwwelettric80com

ITALY middot USA middot SWEDEN middot UK middot AUSTRALIA middot POLAND

Elettric 80 Inc8100 Monticello AvenueSkokie IL 60076 USAPhone +1 847 329 7717e80usaelettric80it

Freewayreg is based on a simple idea

C

M

Y

CM

MY

CY

CMY

K

el80_US_verticalpdf 1 2010-09-29 1346

chain application suite which spans from supplier to store shelf and includes warehouse management systems transportation management systems route accounting systems manufacturing execution mobile sales and ERP data collection Trading partner collaboration is increas-ingly important as organizations strive to reduce costs and improve service levels By combining integration solutions with application functionality organizations are able to ensure consistency in business processes and accuracy of information exchanged with trading partners

ldquoTrueCommerce has fi lled a unique need in the market for simple robust and affordable EDI solutions for small and midsized businessesrdquo said Nick Manolis TrueCom-merce CEO ldquoI am excited for the TrueCommerce team to join HighJump while continuing to provide excellent service support and product innovation to our customersrdquo

ldquoCombining HighJump and TrueCommerce creates a unique and compelling solution offering within the supply chain software marketrdquo said Russell Fleischer HighJump Software CEO ldquoOur view is that supply chain applications must allow users to connect with a broad ecosystem of trading partners to maximize value The TrueCommerce solution platform and our previous move to cloud-based applications will help translate this vision into reality for our customersrdquo

SUPPLY CHAIN NEWS ANALYSIS

Final thoughts on Supply Chain Reset conferenceBY BOB TREBILCOCK EXECUTIVE EDITOR

DESPITE SIGNS OF IMPROVEMENTS doing business in in materials handling remains a challenge At the same time many of the leading customers are investing in supply chain software and automated materials handling systems to improve their businesses That suggests better times are coming

Tom Brokaw punctuates the 25th anniversary of the Material

Handling and Logistics Conference by HK Systems

mmh1010_newsindd 10 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 11

Leader of the PackThe originator of high speed narrow belt sortationTGW Systems has led the way in offering provenadvantages over conventional sortation for over 10 years

NBS fromTGW Systems

50 less install time60 less energy75 less noise

100 of the Value

wwwtgw-groupcom

TGW Systems (formerly TGW-Ermanco) is an integrated logistics solutions and material handling equipment provider The Ermanco name lives onas the product family name for the conveying andsortation products manufactured in the US

Our worldwide perspective and resources and commitment to innovation product developmentand unparalleled customer service can help you today

Proven track record ndash Over 700 installations around the world have made TGWrsquos Narrow Belt Sorter one of the most reliable sorters available

Rugged durability ndash TGWrsquos NBS sorters operate in some of the harshest distribution environments in the world earning customerrsquos admiration and competitorrsquos respect

Application and layout fl exibility ndash The universal frame on TGWrsquos narrow belt sorter means you can use multiple divert options and easily add divert modules after installation for increased fl exibility

Patented technology ndash Patented sortation technology in the TGWrsquos narrow belt sorter continues to lead the way in effective energy effi cient fl exible sortation

10 08 NBSindd 1 8302010 34008 PM

keep enough labor to run his primary distribution center Two presentations drove this point home The fi rst was from an executive with Tim Hor-tons the Dunkin Donuts of Canada The companyrsquos beautiful new DC in Guelph Ontario is underperforming projections even though the ASRS is

living up to its promises The reason The company canrsquot fi nd enough labor willing to work in its case picking and palletizing operations The other was by Terra Winston a consultant who presented a case study about a proj-ect at PepsiCo to develop the next wave of supply chain leaders Her

Those are the two high level take-aways from Supply Chain Reset the annual logistics conference held last month in Park City Utah sponsored by HK Systems now part of Dematic

ldquoLousyrdquo was the most common response to the dinner-time question ldquoHowrsquos businessrdquo

At the same time the roll call of end user companies that said they had projects in the works or on the drawing board was both a Whorsquos Who of American business with names like Coca-Cola and Kraft and companies many of us may never have heard of or think of as custom-ers of our solutions For example I sat on the van from the airport with a guy from the Los Angeles metro-politan transportation system looking for a new automated storage and retrieval system (ASRS) The Federal Reserve Bank was there investigat-ing storage systems I rode in the van back to the airport with a woman from a producer of honey in Texas who had both an ASRS and auto-matic guided vehicles in her facil-ity and was looking to expand her system

Those are signs of a growing con-fi dence I donrsquot think companies plan multi-million dollar investments in au-tomation if they think the apocalypse is right around the corner

One other anecdotal data point Marc Ducharme a vice president and partner with Axium a supplier of robotic materials handling solu-tions told me that 2009 was a dismal year for implementations but that his company has been swamped with RFPs in 2010 An RFP is not an order but itrsquos a sign

A few other observationsRetaining labor and talent could

be the most important issue facing the industry in the future A week or so before going to Utah I had a con-versation with a vice president of sup-ply chain for a major retailer who told me he is interested in automation because he simply cannot fi nd and

mmh1010_newsindd 11 101310 1049 AM

12 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

point the talent shortage isnrsquot limited just to the shop fl oor

Retrofi tting is a viable solution You know the old saying Every-thing old is new again Wegmanrsquos a Midwestern grocer and Rubber-maid both gave strong presenta-tions about how they replaced ag-ing ASRS cranes to breathe new life into their DCs Meanwhile Anheuser Busch gained new ef-fi ciencies in its Columbus Ohio facility by upgrading a warehouse control system

Everyone loves pallets Based in Iowa Green Line Armor is offering a heavy-duty hybrid woodplastic pallet for permanent pallet pools The 48- x 40-inch pallet has heavier stringers and more deck board coverage than a grocery pallet The lead boards on the top and the bottom of the palletmdashthose most likely to get damaged by a lift truckmdashare manufactured from heavy plastic The pallet has a passive RFID

tag that is used by Green Line Armor to identify the pallet and manage war-ranty services Active RFID tags were installed for John Deere the companyrsquos largest customer to track the location of work in process stored on the pallets between manufacturing processes Eric Renteria the companyrsquos president said the pallets which come with a 10-year warranty can be purchased or leased

in a pooling modelNew players are get-

ting into automation Kip Tygard whose company makes the Tygard Claw a lift truck attachment for mixed case palletizing is investing RampD money to develop an automated version of the Claw Thatrsquos not a big shock Tygard is an OEM But I also had conversations with two very large end users in the wholesale food distribu-

tion business that have designed their own automated systemsmdashone has built and implemented its own ASRS design for freezers for years the other has designed its own case picking application that it intends to put out for bid to the materials handling community Both say they may commercialize their solutions in the future

VERSATILITY MATTERSQuality Wildeck construction and versatility make the V-lifttrade the ultimate lifting solution

In todayrsquos lsquogreenrsquo building designs floor space is at a premium and moving up not out is definitely preferred Look no further than the V-Lifttrade from Wildeck ndash the industry leader in space optimization The single cylinder hydraulic system eliminates all moving hoses cables and chains Fewer components means easy installation reduced maintenance and longer service life To get more value out of your operation contact a Wildeck representative today

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MEZZANINESCapacity Matters Efficiency Matters

LIFT SYSTEMSSafety MattersGUARDING PRODUCTS

able to make better decisionsmdashespecially in the case of the unexpected ldquoWhen a shipment is held up at the portrdquo says Prashant Bhatia director of solutions management at SAP ldquoit can trigger logic back to say that Irsquove got a problem I can no longer allocate that inventory on that particular shipment as I thought I couldrdquo

3 One database one system one supply chain In the last few years soft-ware providers have been pulling all of their products onto a single supply chain process platform ldquoItrsquos fairly newrdquo says Lamphier ldquoVarious components have been integrated into that supply chain process platform longer than others but actually moving our WMS onto it has been a more recent developmentmdashjust within the last quarter or twordquo

SAP uses its enterprise resource planning (ERP) system as the central repository of information of supply and demand as well as inventory for the entire supply chain And the modules all

talk to each other Transportation man-agement systems (TMS) in conjunction with the event management modules help optimize freight determine pick-up windows determine carriers keep track of in-transit times and create ASNs

That ASN not only gets sent back to the ERP for visibility but it also gets sent to the WMS where the sys-tem uses the information to plan labor equipment and resources at the receiv-ing dock When the physical product arrives logic within the WMS based on the receipt of goods determines matches against actual demand

Smarter speedier equipment With more retailers crossdocking

over 50 of their items at the case level to their stores equipment innovations have centered on conveyor sortation systems print and apply mechanisms and automatic identifi cation technolo-gies Here are three new equipment

advances1 Smaller gaps and self-regulat-

ing conveyors In the last year the sliding shoe sorter has undergone note-worthy transformations ldquoBy doing a par-allel divert we can now run the packages closer together and get a higher through-put on the same systemrdquo reports Ken Ruehrdanz manager for Dematicrsquos distri-bution and warehousing markets

The sliding shoes that used to physi-cally push the cartons off the sorter at an angle can now run those shoes in parallel enabling smaller gaps between cartonsmdashwhich were previously from 6 inches to 8 inchesmdashdown to 3 inches

With more dense traffi c on conveyors crossdock operators can run their con-veyors at a lower speed while still achiev-ing the same throughput Slower speeds equal less wear and tear decreased energy usage and less maintenance

Another conveyor breakthrough is automatic speed control ldquoThe whole

m m h c o m MODERN MATERIALS HANDLING A P R I L 2 0 1 0 49S

MMH100401sup_Crossdock_ID 49 482010 113620 AM

Leading customers are investing in software and automated

systems to improve business according to attendees of the

Supply Chain Reset conference

mmh1010_newsindd 12 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 13

THE INDUSTRIAL REAL ESTATEmarket is taking steps in the right direction according to a report recently issued by global real estate fi rm Jones Lang LaSalle (JLL wwwjoneslanglasallecom) which report-ed the national average vacancy rate for the North American industrial real estate sector fell from 106 in the fi rst quarter to 104 in the second quarter Despite the slight decline in vacancy the fragile economy still looms large due to declining con-sumer confi dence the drying up of economic stimulus funding and the potential threat of a double-dip recession the report noted

ldquoWe have seen a positive absorp-tion in the vacancy rate in the second quarter but we are very concerned

going forwardrdquo Craig Meyer managing director and leader of JLLrsquos Logistics and Industrial Services Group told Modern ldquoAny kind of sustained demand-driven component in the industrial real estate market is going to be driven by jobs We are just not seeing any of that It is going to be a long slow recoveryrdquo

Looking at base indicators like the Institute of Supply Managementrsquos Manufacturing Index Consumer Confi dence data and industrial real estate vacancy and absorption rates there does not appear to be what Meyer labeled as a strong indication of a positive upswing on the horizon

The report says that a need to restock inventories that were running at 50-year lows resulted in large com-panies strategically capturing high

quality logistics space at cyclically low rates And with slow levels of leasing activity and sparse construc-tion industrial real estate optionsmdashespecially in the Class A large block sectormdashare limited in some markets

And the swift correction in invento-ries during the second half of 2009 and fi rst quarter of 2010 has left inventory levels lean and ready for expansion provided sales rebound in the coming months Should this occur it could lead to increased industrial and logistics real estate leasing activity

The report also pointed out that the initial recovery in the economy was largely driven by improvements in the manufacturing sector and cyclical adjustments in inventories But with the recovery now becoming more broad-based the recent slowdown of inven-tory building could have more of an impact on the industrial property sector than the offi ce sector the report noted

Date 090910 Client Rehrig Pacifi c Job 08312010 File Name 0831_RPC_SlipSheet_Ad_MMH_Oct10 Round

Account Director Niki Phan Designer Revised By ov Editor Production ov

Color 4CProcess Trim 7 times 4625 Bleed 0 Safety 675times 4375 Fold na

Publication(s) TBD Run Date(s) TBD

Approved By

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Available in standard or custom sizes with a variety of surface textures and embossed patterns Rehrig Slip Sheets provide superior slide resistance keeping goods securely in place Manufactured from nearly 100 recycled material each sheet is also 100 recyclable

Beyond the sale Rehrig can help you develop a customized re-use or buy-back program further lowering your average cost per trip

Phone (800) 546-4993 Email inforehrigpacificcom Web wwwrehrigpacificcom

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WAREHOUSESDCS

Industrial real estate market making progress challenges remain

mmh1010_newsindd 13 101310 1049 AM

14 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

ldquoWe are also concerned about seasonality with the holiday season coming uprdquo said Meyer ldquoThe indica-tions we are getting are that we may not see as much preparation for that as we hoped A lot of retailers are saying they are restocked and if consumer confi dence is going down they are not going to build up inventories And for larger big box companies they will see declining values in rents but the availability of product for them to lease is diminishingrdquo

As a result Class A big box dis-tribution space is becoming more diffi cult to fi nd in this economy said Meyer But the build-to-suit market could come back for major retailers as evidenced by a new 1-million-square-foot DC space deal by Amazoncom in Harrisburg Pa and a 14-million-square-foot location in Phoenix

But for a mid-sized industrial building in the 100000-to-150000-square-foot range Class B-sized build-

ing Meyer said there are an infi nite number of these on the market

Looking ahead Meyer said there will still be downward pressure on pric-

ing a double-digit vacancy rate and no increases in lease rates which he noted are actually weakening a little bit and tend to lag a recovery

Power AND CoNtrol

Introducing the latest innovations for incorporating Power AND Control into

your 24 VDC conveyor system

For over 60 years Itoh Denki has been the proven leader in the development and manufacture of superior motorized rollers and components This history provides you confidence in your 24V conveyor applications and designs a confidence based on the component integrity offered by the only sole source motor and control manufacturer in the industry

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LIFTrdquoBFL lifts are designed to move large loads ormultiple pallets betweenfloors These lifts willtravel from 8 feet to 18feet and have platformsizes ranging from 6rsquo x 8rsquo up to 8rsquo x 12rsquoThey are ideal for movinglarge loads 1-2 floors orup to high stages andmezzanines

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BFL AD MMH APRIL 92710 358 PM Page 1

CROWN EQUIPMENT Corp has quali-fi ed 20 of its electric models to operate with various fuel cells bringing the total of qualifi ed combinations of fuel cell packs and trucks to 29 In 2009 Crown (wwwcrowncom) was the fi rst lift truck manufacturer to introduce a fuel cell qualifi cation program

Eric Jensen Crownrsquos manager of new technology research and de-velopment told Modern that the companyrsquos fuel cell qualifi cation pro-gram duplicates its own testing and is conducted at a 25000-square-foot research facility near Dayton Ohio Through the testing process engi-

neers evaluate fuel cell performance and monitor whether issues develop that affect the truckrsquos operation

To qualify a fuel cell pack and truck combination Crownrsquos engineers review key performance metrics for a battery-powered truck such as traction plug-ging and lift and travel speeds Then they replace the battery with a fuel cell power pack and measure the same indicators Through modeling and ap-plication testing the research team de-termines design modifi cations needed to ensure the fuel cell-powered forklift matched standards to which the truck was designed

LIFT TRUCKS

Crown unveils 20 electric lift trucks to operate with fuel cells

mmh1010_newsindd 14 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 15

ldquoWersquove been steadfast in our posi-tion that deployment of a fuel cell forklift fl eet must be carefully evalu-ated and tested for appropriate use in a warehouserdquo said Jensen ldquoThis research-based approach means that our customers can confi dently know they have the right truck for their chosen fuel cell allowing them to meet their performance safety and

environmental sus-tainability goalsrdquo

Crown continues to work closely with fuel cell manufactur-ers and customers to qualify trucks as new fuel cell pack models are intro-duced ldquoForklifts are a key early market for fuel cellsrdquo said Lisa Callaghan Jerram senior market analyst for Fuel Cell Today a leading analyst

fi rm providing market-based research on the fuel cell industry ldquoBased on our market research we have found strong growth in this sector in the past three yearsrdquo

Because fuel cell powered electric forklifts give off exhaust in the form of moist warm air IC truck custom-ers are looking to this technology

so they donrsquot have to deal exhaust issues Jensen said Another advan-tage pointed out by Jensen is a fuel cell powered truckrsquos ability to effec-tively operate in a cold environment because they generate their own heat and the power doesnrsquot fall off like a traditional battery

While the upfront hardware cost of fuel cells is more expensive than a traditional battery Jensen pointed out the potential to capture savings in labor battery changes battery rooms and heating and venting With fuel cells he said a facility doesnrsquot need a battery room and all that goes in to running it properly Instead there is an ongoing savings associated to using fl oor space for production or other value-added operations

ldquoFuel cells have always been talked about fi ve years into the future but we have customers who are [currently] planning installations around this prod-uctrdquo said Jensen ldquoThe future is hererdquo

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To qualify a fuel cell pack and truck combination engineers

review key performance metrics

mmh1010_newsindd 15 101310 1049 AM

lift truck TIPS

GraphicCaption

In the right application tuggers and carts can be a fast and efficient solution

Level the playing field

Football season is under-way and fans are hoping for breakout performances

from stars and rookies alike On the gridiron an overpowered player can be a distinct advan-tage In the warehouse how-ever too much power can lead to waste danger and sluggish performance For some corpo-rations this fact has prompted consideration of fork-free envi-ronments where versatile and custom-built carts and tuggers can do the work faster and more efficiently than their big-ger cousins

Disposing of expensive and powerful equipment in favor of carts may seem counter-intuitive but Jill Burrow marketing manager for Topper Industrial says certain warehouses might benefit greatly from the switch For operations requiring multiple trips between the same areas carts can cut travel time sig-nificantly According to Ed Brown president of Topper Industrial a tugger can pull as many as 13 carts In addi-tion says Brown carts and tuggers can be easier to use than many forklifts

ldquoA forklift costs five times as much but a forklift opera-tor also costs five times more than a tugger operatorrdquo says Brown ldquoAnyone can grab a tugger and gordquo

Once a forklift drops off a pallet in many cases a picker must bend to access product or arrange for the pallet to be lifted Carts on the other hand can be configured with swiveling or angled platforms to allow pickers fast and comfortable access to products Worker safety issues tied to forklifts that operate in tight areas such as poor visibility when driving in re-verse and dock mishaps can also be greatly reduced

ldquoCompanies looking at carts are looking at the cost of equipment and the cost of maintenance but theyrsquore also looking at safetyrdquo says Brown

In addition to ergonomics and safety a fork-free zone might help a warehouse reduce product loss and equip-ment damage Carts provide a secure cradle for moving product while some fork-borne loads are prone to top-pling And forklifts often 10 times as heavy as a tugger and cart setup have a way of proving their strength by leaving dings and dents on storage racks and other hap-less stationary objects

With carts and tuggers Brown says most companies see a return on investment within a year In football a first-round draft pick can cost millions over a multi-year contract before he produces the desired results For com-panies not looking to attempt such a Hail Mary tuggers could prove an efficient alternative

Josh Bond is a contributing editor to Modern and can be reached at turbobondgmailcom

16 O c t O b e r 2 0 1 0 Modern Materials Handling m m h c o m

lift truck TIPS

By Josh Bond Contributing Editor

MMH1010_LiftTruckTipsindd 16 101310 942 AM

MM100601Adsindd 3 6310 349 PMMMH1010_Adsindd 17 101210 1053 AM

18 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

Keith arntson vice president of distribution operations for

del Monte Foods

Four conveyor-topped vehicles ferry loads from an adjacent manufacturing plant

MMH1010_SystemRptDelMonteindd 18 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

bull Discover the newest robotics products and services bull See the latest robot-based solutions for picking and palletizing bull Understand how intelligent robots are revolutionizing processing

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ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

Denso RoboticsElite EngineeringFANUC RoboticsFood EngineeringGenesis Systems GroupHartness InternationalKIva Systems

Modern Materials HandlingMotion Control RoboticsNational InstrumentsOmron Scientifi c Technologies IncRobotics TrendsWind RiverYaskawa Motoman Robotics

MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

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SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 3: Modern Materials Handling - October 2010

+ = Synergy pure and simple

MMH1010_Adsindd 2 101210 1056 AM

Dematic Group a leading global supplier of integrated materials handling solu-tions and services has successfully completed the acquisition of HK Systems a North american automated materials handling and soft-ware solutions provider this strategic union was made final on Sept 15 2010

John K Baysore ceo of Dematic North america (wwwdematicus) will be responsible for leading and developing the newly combined company in the united States and canada With more

than 20 years of executive experience Baysore will lead Dematic in the design delivery and support of a more robust and diversified solution offering to the companyrsquos customers the newly combined company will be called Dematic with its North american headquarters in Grand rapids mich the expanded manufacturing foot-

print will allow Dematic to domestically manufacture automated storage and retrieval machines and automated guided vehicles in addition to conveyor sortation and order fulfillment technology

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 3

Lift trucK DiStriButor Barclay Brand ferdon is supporting National Breast cancer awareness month by raising money and awareness the distributor is displaying a pink painted Yale lift truck on its front lawn through the month of october and they plan to participate in the american cancer Societyrsquos ldquomaking Strides against Breast cancerrdquo walk in Woodbridge center (Woodbridge NJ) on oct 17

ldquoWe have pledged to match all of the donations made by our employeesrdquo said Skip russo president and ceo of Barclay Brand ferdon ldquoi am proud of the people

who work for Barclay although it has been a tough economy for all of us our employees have really stepped up to make a difference in our community Wersquove also had a great response from our vendors in support of this effortrdquo Barclay Brand ferdon is a distributor in New Jersey and New York for all warehousing equipment and support services

Pink lift truck supports breast cancer awareness month

1913the number of exhibiting companies at PaCK eXPo international oct 31 to Nov 3 at mccormick place in chicago

dematic group completes acquisition of HK systems

new player in the carousel market

FAST FACT

UP FRONT B r e a k i n g n e w s y o u s h o u l d k n o w

CeMa report says booked orders were down in July

a NeW proviDer Sapient automation is entering the market for vertical and horizontal carousels and vertical lift modules (vLms) according to ed romaine chief marketing officer for Sapient (wwwgetsapientcom) romaine announced the formation of the new company

at the fall meeting of the material Handling industry of america (mHia) in palm Springs calif the new com-pany is a subsidiary of mDci a pro-vider of industrial automation solu-

tions to the uS postal Service ldquoWe launched the company in Januaryrdquo romaine said ldquoand wersquove spent the last nine months ramping uprdquo While the company is a new player

romaine said Sapient has completed its first sale to an industrial facility in the healthcare industry

iN itS LateSt moNtHLY report the conveyor equipment manufacturers association (cema wwwcemanetorg) reported its July 2010 Booked orders index was 131 the index in July is down 36 points or 22 from June 2010rsquos index of 167 While down from June the July 2010 index represents an increase of 49 from the July 2009 index of 88

What does this mean Bob reinfried cemarsquos executive vice president said the conveyor industry had a very good month While down from June July 2010 was still better than July 2009 itrsquos too early to tell if numbers will continue to climb cema is forecasting an increase of 2 to 3 for the North american conveyor market in 2010

Baysore

MMH1010_Upfrontindd 3 101210 158 PM

wwwhyundai-cecom

Beyond the LimitsHyundairsquos cutting-edge technology is the new criteria of

forklift trucks

HEAD OFFICE(REP of KOREA) Tel 82 2 746 4526 Fax 82 2 746 7444~5 E-mail jcjunghhicokr wwwhyundai-cecom

HCE AMERICAS(USA) Tel 1 847 437 3333 Fax 1 847 437 3574 wwwhceamericascom HHI EUROPE(BELGIUM) Tel 32 14 56 2200 Fax 32 14 59 3405~6 wwwhyundaieu HHI BEIJING(CHINA) Tel 86 10 8321 3377 Fax 86 10 5143 8502 wwwhyundai-bjcom

DUBAI BRANCH OFFICE(UAE) Tel 971 4 425 7995 Fax 971 4 425 7996 E-mail sbyunhhicokr

ISTANBUL BRANCH OFFICE(TURKEY) Tel 90 212 345 1261~2 Fax 90 212 345 1263 E-mail eunsoohhicokr

MOSCOW BRANCH OFFICE(RUSSIA) Tel 7 495 258 1381 Fax 7 495 258 1382 E-mail leokanghhicokr

FORKLIFT LINE-UP

LPG Forklift 15 - 45Ton Battery Forklift (Counter Balanced) 16 - 5Ton

Reach Truck (Seated) 14 - 25TonReach Truck (Standing) 1 - 25Ton Electric Towing Platform Truck40TA-715PA-7

Diesel Forklift 15 - 18Ton

MMH1010_Adsindd 4 101210 1053 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 5

PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION WAREHOUSING AND MANUFACTURING

VOL 65 NO 10

DEPARTMENTS amp COLUMNS 3 Upfront 7 This Month in Modern16 Lift Truck Tips Level the playing field38 Focus On Palletizers42 Supplement WarehousesDCs50 60 seconds with

NEWS 9 MHIA Growth is back 9 HighJump to acquire TrueCommerce10 Final thoughts on Supply Chain Reset13 Industrial real estate market making

progress challenges remain

14 Crown unveils 20 electric lift trucks to operate with fuel cells

COVER STORYSYSTEM REPORT

18 Best in classDel Monte Foodsrsquo new Topeka DC brings laser-guided AGVs from manufacturing into distribution The result is a best-in-class materials handling system that minimizes costs with room to expand in the future

22 Automatic guided vehicles streamline operationsLaser-guided AGVs move product from the manufacturing plant and through the distribution center

FEATURESPRODUCTIVITY SOLUTION

25 Tilt toward safety and productivityAluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

SPECIAL REPORT

26 Top 20 automatic data capture suppliersThe ADC market took a significant hit in 2009 but the recovery may already be underway

INFORMATION MANAGEMENT

30 In sync Data capture and mobile computing Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

EQUIPMENT REPORT

34 Carousels Turning picking into productivityNot just for high-density storage anymore todayrsquos carousels are delivering product to the person while increasing productivity reducing labor saving space and cutting energy costs

60 seconds with Joan Barrett Kellogg p 50

Modern Materials Handling reg (ISSN 0026-8038) is published monthly by Peerless Media LLC a Division of EH Publishing Inc 111 Speen St Suite 200 Framingham MA 01701 Annual subscription rates for non-qualifi ed subscribers USA $119 Canada $159 Other International $249 Single copies are available for $2000 Send all subscription inquiries to Modern Materials Handling 111 Speen Street Suite 200 Framingham MA 01701 USA Periodicals postage paid at Framingham MA and additional mailing offi ces POSTMASTER Send address changes to Modern Materials Handling PO Box 1496 Framingham MA 01701-1496 Reproduction of this magazine in whole or part without written permis-sion of the publisher is prohibited All rights reserved (C)2010 Peerless Media LLC

reg

PHOTO BLAINE FISHERGETTY IMAGES

Keith Arntson and his team at Del Monte put a fl eet of laser-guided AGVs to work at their DC

handling system that minimizes costs with room to expand in the future

60 seconds with Joan Barrett Kellogg p 50

BLAINE FISHERGETTY IMAGES

MMH1010_TOCindd 5 101310 947 AM

Introducing the new Automatic Destratification System

Big Ass Fans have always saved money in the winter but now it can be done with the push of a button The patent pending Automatic Destratification System keeps your space at the perfect temperature year-round from floor to ceiling The Automatic Destratification System calculates the floor-to-ceiling temperature differential and modulates the fanrsquos speed so you donrsquot have to

Bottom line you could save up to 30 on your heating bills this winterhellip and next winterhellip and next winterhellip

pending Automatic Destratification System keeps your space

Bottom line you could save up to 30 on your heating bills

NEWNEWNEW

Visit wwwBigAssFanscom or call 877-BIG FANS (877-244-3267) to learn moreAn ISO 90012008 certified company

If global warming doesnrsquot reduce your energy costs this winter perhaps we can help

Covered by one or more of the following US Patents 6244821 6589016 6817835 6939108 7252478 7284960 7654798 D587799 D607988 and other patents pending

10 year parts 1 year labor warranty certain exclusions apply See complete warranty for details copy 2010 Delta T Corporation dba The Big Ass Fan Company All rights reserved

BAF_MMH_DestratAd_091610indd 1 91710 851 AMMMH1010_Adsindd 6 101210 1053 AM

EDITORIAL OFFICES111 Speen Street Suite 200Framingham MA 01701-1496(800) 375-8015

Michael LevansGROUP EDITORIAL DIRECTOR mlevansehpubcom

Bob TrebilcockEXECUTIVE EDITOR

roberttrebilcockmyfairpointnet

Noeumll P BodenburgEXECUTIVE MANAGING EDITOR

nbodenburgehpubcom

Lorie King RogersASSOCIATE EDITOR

lrogersehpubcom

Sara Pearson SpecterEDITOR AT LARGE

saramoxiemarketingllccom

Roberto MichelEDITOR AT LARGE

robertomichelnewrrcom

Tom AndelCOLUMNIST

tandel4315aolcom

Jeff BermanGROUP NEWS EDITOR

jbermanehpubcom

Josh BondCONTRIBUTING EDITOR

turbobondgmailcom

Mike RoachCREATIVE DIRECTOR

mroachehpubcom

Wendy DelCampoART DIRECTOR

wdelcampoehpubcom

Daniel GuideraILLUSTRATION

danieldanielguideracom

Brian CeraoloGROUP PUBLISHER bceraoloehpubcom

EDITORIAL ADVISORY BOARD

Ron Giuntini OEM PRODUCT-SERVICES INSTITUTE

John HillESYNC

TRANSYSTEMS

Susan RiderRIDER amp ASSOCIATES

Ken RuehrdanzDEMATIC

Dr John Usher UNIVERSITY OF LOUISVILLE

Col Alan B Will2D MARINE LOGISTICS GROUP

Brett WoodTOYOTA MATERIAL HANDLING USA

Peerless Media LLCA DIVISION OF EH PUBLISHING INC

Kenneth MoyesPRESIDENT AND CEOEH PUBLISHING INC

Brian CeraoloPUBLISHER AND EXECUTIVE VICE PRESIDENT

PEERLESS MEDIA LLC

MAGAZINE SUBSCRIPTIONSStart renew or update your FREE magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPhone 1-800-315-1578Mail Peerless Media PO Box 1496 Framingham MA 01701

eNEWSLETTER SUBSCRIPTIONSSign up or manage your FREE eNewsletter subscriptions at wwwmmhcomenewsletters

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 7

reg

Member Member ofOfficial Publication of

Winner Jesse H Neal

Certificates of Merit for Journalistic

Excellence

EDITORIAL OFFICES111 Speen Street Suite 200Framingham MA 01701-1496(800) 375-8015

Michael LevansGROUP EDITORIAL DIRECTOR mlevansehpubcom

Bob TrebilcockEXECUTIVE EDITOR

roberttrebilcockmyfairpointnet

Noeumll P BodenburgEXECUTIVE MANAGING EDITOR

nbodenburgehpubcom

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lrogersehpubcom

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jbermanehpubcom

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saramoxiemarketingllccom

Roberto MichelEDITOR AT LARGE

robertomichelnewrrcom

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turbobondgmailcom

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mroachehpubcom

Wendy DelCampoART DIRECTOR

wdelcampoehpubcom

Daniel GuideraILLUSTRATION

danieldanielguideracom

Brian CeraoloGROUP PUBLISHER bceraoloehpubcom

EDITORIAL ADVISORY BOARD

Ron Giuntini OEM PRODUCT-SERVICES INSTITUTE

John HillESYNC

TRANSYSTEMS

Susan RiderRIDER amp ASSOCIATES

Ken RuehrdanzDEMATIC

Dr John Usher UNIVERSITY OF LOUISVILLE

Col Alan B Will2D MARINE LOGISTICS GROUP

Brett WoodTOYOTA MATERIAL HANDLING USA

Peerless Media LLCA DIVISION OF EH PUBLISHING INC

Kenneth MoyesPRESIDENT AND CEOEH PUBLISHING INC

Brian CeraoloPUBLISHER AND EXECUTIVE VICE PRESIDENT

PEERLESS MEDIA LLC

MAGAZINE SUBSCRIPTIONSStart renew or update your FREE magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPhone 1-800-315-1578Mail Peerless Media PO Box 1496 Framingham MA 01701

eNEWSLETTER SUBSCRIPTIONSSign up or manage your FREE eNewsletter subscriptions at wwwmmhcomenewsletters

MICHAEL LEVANSGROUP EDITORIAL

DIRECTOR

THIS MONTH IN MODERN

While it may be at a much slower pace than predicted growth is actually taking place whether

yoursquore feeling it or not In fact we kick off this monthrsquos issue with the latest report from the Material Handling Industry of America that forecasts equipment orders to grow 12 to 14 in 2010 if the current momen-tum persists (page 9)

Mind you those new numbers are com-ing off 2009 when orders saw a 343 de-cline from 2008 But any way we position the latest forecast we canrsquot help but see it as positive news for the industry overall It may even help to crack a few smiles

But while numbers donrsquot lie they can of-ten be deceiving Even though it appeared that equipment orders fell off a cliff two years ago that didnrsquot mean that materials handling professionals went into hiberna-tion in terms of executing improvement projects

In his thoughtful wrap up of HK Systemsrsquos recent Material Handling and Logistics Con-ference (page 10) executive editor Bob Tre-bilcock recounts a number of conversations that he had with attendees who were eager to share the details of the projects that they completed over the past 18 months or moved to the front burner over the past six months There was a local authority looking to put in a new ASRS the Federal Reserve Bank was investigating storage systems and even a specialty foods manufacturer looking to expand a fl eet of AGVs

ldquoI donrsquot think companies plan multi-million dollar investments in automation if

they think the apocalypse is right around the cornerrdquo observes Trebilcock

My fi rm belief that innovation never goes out of stylemdashno matter what the economic environment may bemdashhas been further validated in the system reports that have graced Modernrsquos covers over the past two years Offi ce Depot Kroger Crate amp Barrel Patagonia Bon-Ton Stores The Ap-parel Group IKEAhellipand the list goes on Each of these innovation mavericks has put precious time and strategic thought into materials handling projects that will put them in a distinct competitive advantage as the economic fog begins to clear

Itrsquos safe to say that the brutal economy never once stopped Keith Arntson vice president of distribution operations for Del Monte Foods from thinking how to he could help take miles out of the food giantrsquos distribution network by applying a few new innovations inside his To-peka Kan DC In fact after reading this monthrsquos System Report (page 18) you can say that Arntson has fl ipped over a few materials handling axioms en route to a stunning success

This month Irsquom going to leave Modern readers with a challenge After reading the Del Monte success story Irsquod like you to share with us a few of the innovation projects that yoursquove conducted during the past 18 months We believe that innovation never goes out of style now help us spread the good word and inspire a few of the late adopters Please send me an email on your better idea(s) mlevansehpubcom

Innovation never goes out of style

MMH1010_Editorialindd 7 101310 254 PM

Modern Materials Logistics Management Supply Chain Management

bull Automation

bull Conveyors amp Sorters

bull Inventory amp Picking

bull Loading Dock Equipment

bull Mobile amp Wireless

bull Shipping Pallets

bull Storage Systems

bull Containers amp Totes

bull Energy amp Sustainability

bull Lift Truck amp Fork Lift

bull Handling amp Warehouse Ergonomics

bull Packaging

bull Software amp Technology

wwwmmhcomcriticaltopics

Critical Industry News at Your Fingertips

Critical Topic areas help you develop strategies and expand your knowledge Each topic provides you with the news information and resources you need mdash each day

CRITICAL TOPICS

Modern Materials Logistics Management Supply Chain Management

MMH_CriticalTopics_Houseindd 1 81010 117 PMMMH1010_Adsindd 8 101210 1053 AM

ITrsquoS STILL A FAR CRY FROM 2007 but the materials handling industry is growing once again Following a 343 decline in equipment orders in 2009 the Material Handling Industry of America (MHIA wwwmhiaorg) is forecasting equipment orders to grow 12 to 14 in 2010 if the current momentum continues

A variety of factors are driving growth in manufacturing warehous-ing and distribution on a global basis especially an increase in industrial pro-duction in the fi rst half of 2010 despite factory utilization rates that remain very low by historical comparison

ldquoConsumer demand has not returnedrdquo Hal Vandiver executive vice president of business develop-ment for MHIA told Modern during the associationrsquos fall meeting ldquoBut in the fi rst two quarters the economy shifted from recession into recovery mode fi lling supply chain pipelines re-establishing inventories and re-sponding to pent up demandrdquo

While Vandiver expects the indus-try to continue to grow by 11 to 12 in 2011 drags on the economy continue ldquoForecasts are now calling for a combination of reduced GDP corporate profi t business investment and output growth with industrial utilization remaining below 75 until

late 2011rdquo Vandiver said ldquoThis is largely due to uncertainty Consumers inves-tors and business owners need greater confi dence in the economyrsquos ability to sustain positive growthrdquo For those reasons Vandiver doesnrsquot expect a signifi cant return to the kinds of num-bers the industry posted in the past up until 2007

In addition to

a growth in orders for new equipment Van-diver forecasts material handling shipments to grow 3 to 4 in 2010 and another 10 to 11 in 2011 Domestic demand defi ned as shipments plus imports less exports will grow by 1 in 2010 and by 10 to 11 in 2011 Exports will be stronger than im-ports in 2010 and 2011 refl ecting stronger indus-trial growth in emerging markets outside North America

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 9

Company Briefi ngs | Bob Trebilcock

The age of automationExpressed as an equation The industrial age + the information age = the automation age

mmhcomblogsautomation

Diblogbest of Modernrsquos blogs

BY BOB TREBILCOCK EXECUTIVE EDITOR

ECONOMY

MHIA Growth is backMHIA FORECASTS 12 TO 14 GROWTH IN NEW EQUIPMENT ORDERS IN 2010

0

-343

2009 2010

130(forecast)

MHIA equipment orders forecast

Source Material Handling Industry of America (MHIA)

HIGHJUMP SOFTWARE announced today that it has reached agreement to acquire TrueCommerce a provider of business-to-business integration solutions TrueCommerce provides a comprehensive end-to-end suite of trading partner connectivity solutions including electronic data interchange (EDI) translation and data mapping software transaction network and on-boarding services HighJump Software (wwwhighjumpcom) ranks

No 11 on Modernrsquos 2010 Supply Chain Management Software an-nual list with $85 million in revenue TrueCommercersquos solutions enable trading partner connectivity for 3000 customers feature predefi ned inte-gration to many major ERP systems and can be deployed in either SaaS or on-premise models

The TrueCommerce trading part-ner integration solution complements HighJump Softwarersquos existing supply

MampA

HighJump to acquire TrueCommerce

mmh1010_newsindd 9 101310 1049 AM

middot Robotic palletizing cells handle goods at the end of the production linemiddot LGVs transport pallets to stretch wrapping and labelingmiddot LGVs transport finished pallets to the warehousemiddot LGVs for Storage amp Retrieval (SRS)middot LGVs for Auto-Trailer Loading (ATL)middot An integrated software management system

Elettric 80 is a global provider of end-of-lineautomation solutions These solutions are called Freewayreg material handling system

The technologies are adaptable and have a high degree of built-in flexibility which makes them suitable for any plant warehouse layout or design More details explanatory videos and animations can be found at wwwelettric80com

ITALY middot USA middot SWEDEN middot UK middot AUSTRALIA middot POLAND

Elettric 80 Inc8100 Monticello AvenueSkokie IL 60076 USAPhone +1 847 329 7717e80usaelettric80it

Freewayreg is based on a simple idea

C

M

Y

CM

MY

CY

CMY

K

el80_US_verticalpdf 1 2010-09-29 1346

chain application suite which spans from supplier to store shelf and includes warehouse management systems transportation management systems route accounting systems manufacturing execution mobile sales and ERP data collection Trading partner collaboration is increas-ingly important as organizations strive to reduce costs and improve service levels By combining integration solutions with application functionality organizations are able to ensure consistency in business processes and accuracy of information exchanged with trading partners

ldquoTrueCommerce has fi lled a unique need in the market for simple robust and affordable EDI solutions for small and midsized businessesrdquo said Nick Manolis TrueCom-merce CEO ldquoI am excited for the TrueCommerce team to join HighJump while continuing to provide excellent service support and product innovation to our customersrdquo

ldquoCombining HighJump and TrueCommerce creates a unique and compelling solution offering within the supply chain software marketrdquo said Russell Fleischer HighJump Software CEO ldquoOur view is that supply chain applications must allow users to connect with a broad ecosystem of trading partners to maximize value The TrueCommerce solution platform and our previous move to cloud-based applications will help translate this vision into reality for our customersrdquo

SUPPLY CHAIN NEWS ANALYSIS

Final thoughts on Supply Chain Reset conferenceBY BOB TREBILCOCK EXECUTIVE EDITOR

DESPITE SIGNS OF IMPROVEMENTS doing business in in materials handling remains a challenge At the same time many of the leading customers are investing in supply chain software and automated materials handling systems to improve their businesses That suggests better times are coming

Tom Brokaw punctuates the 25th anniversary of the Material

Handling and Logistics Conference by HK Systems

mmh1010_newsindd 10 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 11

Leader of the PackThe originator of high speed narrow belt sortationTGW Systems has led the way in offering provenadvantages over conventional sortation for over 10 years

NBS fromTGW Systems

50 less install time60 less energy75 less noise

100 of the Value

wwwtgw-groupcom

TGW Systems (formerly TGW-Ermanco) is an integrated logistics solutions and material handling equipment provider The Ermanco name lives onas the product family name for the conveying andsortation products manufactured in the US

Our worldwide perspective and resources and commitment to innovation product developmentand unparalleled customer service can help you today

Proven track record ndash Over 700 installations around the world have made TGWrsquos Narrow Belt Sorter one of the most reliable sorters available

Rugged durability ndash TGWrsquos NBS sorters operate in some of the harshest distribution environments in the world earning customerrsquos admiration and competitorrsquos respect

Application and layout fl exibility ndash The universal frame on TGWrsquos narrow belt sorter means you can use multiple divert options and easily add divert modules after installation for increased fl exibility

Patented technology ndash Patented sortation technology in the TGWrsquos narrow belt sorter continues to lead the way in effective energy effi cient fl exible sortation

10 08 NBSindd 1 8302010 34008 PM

keep enough labor to run his primary distribution center Two presentations drove this point home The fi rst was from an executive with Tim Hor-tons the Dunkin Donuts of Canada The companyrsquos beautiful new DC in Guelph Ontario is underperforming projections even though the ASRS is

living up to its promises The reason The company canrsquot fi nd enough labor willing to work in its case picking and palletizing operations The other was by Terra Winston a consultant who presented a case study about a proj-ect at PepsiCo to develop the next wave of supply chain leaders Her

Those are the two high level take-aways from Supply Chain Reset the annual logistics conference held last month in Park City Utah sponsored by HK Systems now part of Dematic

ldquoLousyrdquo was the most common response to the dinner-time question ldquoHowrsquos businessrdquo

At the same time the roll call of end user companies that said they had projects in the works or on the drawing board was both a Whorsquos Who of American business with names like Coca-Cola and Kraft and companies many of us may never have heard of or think of as custom-ers of our solutions For example I sat on the van from the airport with a guy from the Los Angeles metro-politan transportation system looking for a new automated storage and retrieval system (ASRS) The Federal Reserve Bank was there investigat-ing storage systems I rode in the van back to the airport with a woman from a producer of honey in Texas who had both an ASRS and auto-matic guided vehicles in her facil-ity and was looking to expand her system

Those are signs of a growing con-fi dence I donrsquot think companies plan multi-million dollar investments in au-tomation if they think the apocalypse is right around the corner

One other anecdotal data point Marc Ducharme a vice president and partner with Axium a supplier of robotic materials handling solu-tions told me that 2009 was a dismal year for implementations but that his company has been swamped with RFPs in 2010 An RFP is not an order but itrsquos a sign

A few other observationsRetaining labor and talent could

be the most important issue facing the industry in the future A week or so before going to Utah I had a con-versation with a vice president of sup-ply chain for a major retailer who told me he is interested in automation because he simply cannot fi nd and

mmh1010_newsindd 11 101310 1049 AM

12 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

point the talent shortage isnrsquot limited just to the shop fl oor

Retrofi tting is a viable solution You know the old saying Every-thing old is new again Wegmanrsquos a Midwestern grocer and Rubber-maid both gave strong presenta-tions about how they replaced ag-ing ASRS cranes to breathe new life into their DCs Meanwhile Anheuser Busch gained new ef-fi ciencies in its Columbus Ohio facility by upgrading a warehouse control system

Everyone loves pallets Based in Iowa Green Line Armor is offering a heavy-duty hybrid woodplastic pallet for permanent pallet pools The 48- x 40-inch pallet has heavier stringers and more deck board coverage than a grocery pallet The lead boards on the top and the bottom of the palletmdashthose most likely to get damaged by a lift truckmdashare manufactured from heavy plastic The pallet has a passive RFID

tag that is used by Green Line Armor to identify the pallet and manage war-ranty services Active RFID tags were installed for John Deere the companyrsquos largest customer to track the location of work in process stored on the pallets between manufacturing processes Eric Renteria the companyrsquos president said the pallets which come with a 10-year warranty can be purchased or leased

in a pooling modelNew players are get-

ting into automation Kip Tygard whose company makes the Tygard Claw a lift truck attachment for mixed case palletizing is investing RampD money to develop an automated version of the Claw Thatrsquos not a big shock Tygard is an OEM But I also had conversations with two very large end users in the wholesale food distribu-

tion business that have designed their own automated systemsmdashone has built and implemented its own ASRS design for freezers for years the other has designed its own case picking application that it intends to put out for bid to the materials handling community Both say they may commercialize their solutions in the future

VERSATILITY MATTERSQuality Wildeck construction and versatility make the V-lifttrade the ultimate lifting solution

In todayrsquos lsquogreenrsquo building designs floor space is at a premium and moving up not out is definitely preferred Look no further than the V-Lifttrade from Wildeck ndash the industry leader in space optimization The single cylinder hydraulic system eliminates all moving hoses cables and chains Fewer components means easy installation reduced maintenance and longer service life To get more value out of your operation contact a Wildeck representative today

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800-325-6939 | WWWWILDECKCOM

MEZZANINESCapacity Matters Efficiency Matters

LIFT SYSTEMSSafety MattersGUARDING PRODUCTS

able to make better decisionsmdashespecially in the case of the unexpected ldquoWhen a shipment is held up at the portrdquo says Prashant Bhatia director of solutions management at SAP ldquoit can trigger logic back to say that Irsquove got a problem I can no longer allocate that inventory on that particular shipment as I thought I couldrdquo

3 One database one system one supply chain In the last few years soft-ware providers have been pulling all of their products onto a single supply chain process platform ldquoItrsquos fairly newrdquo says Lamphier ldquoVarious components have been integrated into that supply chain process platform longer than others but actually moving our WMS onto it has been a more recent developmentmdashjust within the last quarter or twordquo

SAP uses its enterprise resource planning (ERP) system as the central repository of information of supply and demand as well as inventory for the entire supply chain And the modules all

talk to each other Transportation man-agement systems (TMS) in conjunction with the event management modules help optimize freight determine pick-up windows determine carriers keep track of in-transit times and create ASNs

That ASN not only gets sent back to the ERP for visibility but it also gets sent to the WMS where the sys-tem uses the information to plan labor equipment and resources at the receiv-ing dock When the physical product arrives logic within the WMS based on the receipt of goods determines matches against actual demand

Smarter speedier equipment With more retailers crossdocking

over 50 of their items at the case level to their stores equipment innovations have centered on conveyor sortation systems print and apply mechanisms and automatic identifi cation technolo-gies Here are three new equipment

advances1 Smaller gaps and self-regulat-

ing conveyors In the last year the sliding shoe sorter has undergone note-worthy transformations ldquoBy doing a par-allel divert we can now run the packages closer together and get a higher through-put on the same systemrdquo reports Ken Ruehrdanz manager for Dematicrsquos distri-bution and warehousing markets

The sliding shoes that used to physi-cally push the cartons off the sorter at an angle can now run those shoes in parallel enabling smaller gaps between cartonsmdashwhich were previously from 6 inches to 8 inchesmdashdown to 3 inches

With more dense traffi c on conveyors crossdock operators can run their con-veyors at a lower speed while still achiev-ing the same throughput Slower speeds equal less wear and tear decreased energy usage and less maintenance

Another conveyor breakthrough is automatic speed control ldquoThe whole

m m h c o m MODERN MATERIALS HANDLING A P R I L 2 0 1 0 49S

MMH100401sup_Crossdock_ID 49 482010 113620 AM

Leading customers are investing in software and automated

systems to improve business according to attendees of the

Supply Chain Reset conference

mmh1010_newsindd 12 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 13

THE INDUSTRIAL REAL ESTATEmarket is taking steps in the right direction according to a report recently issued by global real estate fi rm Jones Lang LaSalle (JLL wwwjoneslanglasallecom) which report-ed the national average vacancy rate for the North American industrial real estate sector fell from 106 in the fi rst quarter to 104 in the second quarter Despite the slight decline in vacancy the fragile economy still looms large due to declining con-sumer confi dence the drying up of economic stimulus funding and the potential threat of a double-dip recession the report noted

ldquoWe have seen a positive absorp-tion in the vacancy rate in the second quarter but we are very concerned

going forwardrdquo Craig Meyer managing director and leader of JLLrsquos Logistics and Industrial Services Group told Modern ldquoAny kind of sustained demand-driven component in the industrial real estate market is going to be driven by jobs We are just not seeing any of that It is going to be a long slow recoveryrdquo

Looking at base indicators like the Institute of Supply Managementrsquos Manufacturing Index Consumer Confi dence data and industrial real estate vacancy and absorption rates there does not appear to be what Meyer labeled as a strong indication of a positive upswing on the horizon

The report says that a need to restock inventories that were running at 50-year lows resulted in large com-panies strategically capturing high

quality logistics space at cyclically low rates And with slow levels of leasing activity and sparse construc-tion industrial real estate optionsmdashespecially in the Class A large block sectormdashare limited in some markets

And the swift correction in invento-ries during the second half of 2009 and fi rst quarter of 2010 has left inventory levels lean and ready for expansion provided sales rebound in the coming months Should this occur it could lead to increased industrial and logistics real estate leasing activity

The report also pointed out that the initial recovery in the economy was largely driven by improvements in the manufacturing sector and cyclical adjustments in inventories But with the recovery now becoming more broad-based the recent slowdown of inven-tory building could have more of an impact on the industrial property sector than the offi ce sector the report noted

Date 090910 Client Rehrig Pacifi c Job 08312010 File Name 0831_RPC_SlipSheet_Ad_MMH_Oct10 Round

Account Director Niki Phan Designer Revised By ov Editor Production ov

Color 4CProcess Trim 7 times 4625 Bleed 0 Safety 675times 4375 Fold na

Publication(s) TBD Run Date(s) TBD

Approved By

A FAMILY TRADITION OF GROWTH SERVICE AND INNOVATION

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Available in standard or custom sizes with a variety of surface textures and embossed patterns Rehrig Slip Sheets provide superior slide resistance keeping goods securely in place Manufactured from nearly 100 recycled material each sheet is also 100 recyclable

Beyond the sale Rehrig can help you develop a customized re-use or buy-back program further lowering your average cost per trip

Phone (800) 546-4993 Email inforehrigpacificcom Web wwwrehrigpacificcom

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WAREHOUSESDCS

Industrial real estate market making progress challenges remain

mmh1010_newsindd 13 101310 1049 AM

14 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

ldquoWe are also concerned about seasonality with the holiday season coming uprdquo said Meyer ldquoThe indica-tions we are getting are that we may not see as much preparation for that as we hoped A lot of retailers are saying they are restocked and if consumer confi dence is going down they are not going to build up inventories And for larger big box companies they will see declining values in rents but the availability of product for them to lease is diminishingrdquo

As a result Class A big box dis-tribution space is becoming more diffi cult to fi nd in this economy said Meyer But the build-to-suit market could come back for major retailers as evidenced by a new 1-million-square-foot DC space deal by Amazoncom in Harrisburg Pa and a 14-million-square-foot location in Phoenix

But for a mid-sized industrial building in the 100000-to-150000-square-foot range Class B-sized build-

ing Meyer said there are an infi nite number of these on the market

Looking ahead Meyer said there will still be downward pressure on pric-

ing a double-digit vacancy rate and no increases in lease rates which he noted are actually weakening a little bit and tend to lag a recovery

Power AND CoNtrol

Introducing the latest innovations for incorporating Power AND Control into

your 24 VDC conveyor system

For over 60 years Itoh Denki has been the proven leader in the development and manufacture of superior motorized rollers and components This history provides you confidence in your 24V conveyor applications and designs a confidence based on the component integrity offered by the only sole source motor and control manufacturer in the industry

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Intelligent solutions yoursquod expect from Itoh Denki Intelligent solutions yoursquod expect from Itoh Denki

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LIFTrdquoBFL lifts are designed to move large loads ormultiple pallets betweenfloors These lifts willtravel from 8 feet to 18feet and have platformsizes ranging from 6rsquo x 8rsquo up to 8rsquo x 12rsquoThey are ideal for movinglarge loads 1-2 floors orup to high stages andmezzanines

1-800-843-3625wwwadvancel i f ts com

BFL AD MMH APRIL 92710 358 PM Page 1

CROWN EQUIPMENT Corp has quali-fi ed 20 of its electric models to operate with various fuel cells bringing the total of qualifi ed combinations of fuel cell packs and trucks to 29 In 2009 Crown (wwwcrowncom) was the fi rst lift truck manufacturer to introduce a fuel cell qualifi cation program

Eric Jensen Crownrsquos manager of new technology research and de-velopment told Modern that the companyrsquos fuel cell qualifi cation pro-gram duplicates its own testing and is conducted at a 25000-square-foot research facility near Dayton Ohio Through the testing process engi-

neers evaluate fuel cell performance and monitor whether issues develop that affect the truckrsquos operation

To qualify a fuel cell pack and truck combination Crownrsquos engineers review key performance metrics for a battery-powered truck such as traction plug-ging and lift and travel speeds Then they replace the battery with a fuel cell power pack and measure the same indicators Through modeling and ap-plication testing the research team de-termines design modifi cations needed to ensure the fuel cell-powered forklift matched standards to which the truck was designed

LIFT TRUCKS

Crown unveils 20 electric lift trucks to operate with fuel cells

mmh1010_newsindd 14 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 15

ldquoWersquove been steadfast in our posi-tion that deployment of a fuel cell forklift fl eet must be carefully evalu-ated and tested for appropriate use in a warehouserdquo said Jensen ldquoThis research-based approach means that our customers can confi dently know they have the right truck for their chosen fuel cell allowing them to meet their performance safety and

environmental sus-tainability goalsrdquo

Crown continues to work closely with fuel cell manufactur-ers and customers to qualify trucks as new fuel cell pack models are intro-duced ldquoForklifts are a key early market for fuel cellsrdquo said Lisa Callaghan Jerram senior market analyst for Fuel Cell Today a leading analyst

fi rm providing market-based research on the fuel cell industry ldquoBased on our market research we have found strong growth in this sector in the past three yearsrdquo

Because fuel cell powered electric forklifts give off exhaust in the form of moist warm air IC truck custom-ers are looking to this technology

so they donrsquot have to deal exhaust issues Jensen said Another advan-tage pointed out by Jensen is a fuel cell powered truckrsquos ability to effec-tively operate in a cold environment because they generate their own heat and the power doesnrsquot fall off like a traditional battery

While the upfront hardware cost of fuel cells is more expensive than a traditional battery Jensen pointed out the potential to capture savings in labor battery changes battery rooms and heating and venting With fuel cells he said a facility doesnrsquot need a battery room and all that goes in to running it properly Instead there is an ongoing savings associated to using fl oor space for production or other value-added operations

ldquoFuel cells have always been talked about fi ve years into the future but we have customers who are [currently] planning installations around this prod-uctrdquo said Jensen ldquoThe future is hererdquo

Buildings available up to

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Call one of our ClearSpan Specialists at 18666431010 or visit us at wwwClearSpancom Mention code CST1109

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To qualify a fuel cell pack and truck combination engineers

review key performance metrics

mmh1010_newsindd 15 101310 1049 AM

lift truck TIPS

GraphicCaption

In the right application tuggers and carts can be a fast and efficient solution

Level the playing field

Football season is under-way and fans are hoping for breakout performances

from stars and rookies alike On the gridiron an overpowered player can be a distinct advan-tage In the warehouse how-ever too much power can lead to waste danger and sluggish performance For some corpo-rations this fact has prompted consideration of fork-free envi-ronments where versatile and custom-built carts and tuggers can do the work faster and more efficiently than their big-ger cousins

Disposing of expensive and powerful equipment in favor of carts may seem counter-intuitive but Jill Burrow marketing manager for Topper Industrial says certain warehouses might benefit greatly from the switch For operations requiring multiple trips between the same areas carts can cut travel time sig-nificantly According to Ed Brown president of Topper Industrial a tugger can pull as many as 13 carts In addi-tion says Brown carts and tuggers can be easier to use than many forklifts

ldquoA forklift costs five times as much but a forklift opera-tor also costs five times more than a tugger operatorrdquo says Brown ldquoAnyone can grab a tugger and gordquo

Once a forklift drops off a pallet in many cases a picker must bend to access product or arrange for the pallet to be lifted Carts on the other hand can be configured with swiveling or angled platforms to allow pickers fast and comfortable access to products Worker safety issues tied to forklifts that operate in tight areas such as poor visibility when driving in re-verse and dock mishaps can also be greatly reduced

ldquoCompanies looking at carts are looking at the cost of equipment and the cost of maintenance but theyrsquore also looking at safetyrdquo says Brown

In addition to ergonomics and safety a fork-free zone might help a warehouse reduce product loss and equip-ment damage Carts provide a secure cradle for moving product while some fork-borne loads are prone to top-pling And forklifts often 10 times as heavy as a tugger and cart setup have a way of proving their strength by leaving dings and dents on storage racks and other hap-less stationary objects

With carts and tuggers Brown says most companies see a return on investment within a year In football a first-round draft pick can cost millions over a multi-year contract before he produces the desired results For com-panies not looking to attempt such a Hail Mary tuggers could prove an efficient alternative

Josh Bond is a contributing editor to Modern and can be reached at turbobondgmailcom

16 O c t O b e r 2 0 1 0 Modern Materials Handling m m h c o m

lift truck TIPS

By Josh Bond Contributing Editor

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18 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

Keith arntson vice president of distribution operations for

del Monte Foods

Four conveyor-topped vehicles ferry loads from an adjacent manufacturing plant

MMH1010_SystemRptDelMonteindd 18 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

bull Discover the newest robotics products and services bull See the latest robot-based solutions for picking and palletizing bull Understand how intelligent robots are revolutionizing processing

packaging plant operations and material handling bull Learn about robotics solutions that will increase your bottom line

Sponsoring companies include

Register TodaymdashItrsquos FREE Go to robovirtualeventscom

ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

Denso RoboticsElite EngineeringFANUC RoboticsFood EngineeringGenesis Systems GroupHartness InternationalKIva Systems

Modern Materials HandlingMotion Control RoboticsNational InstrumentsOmron Scientifi c Technologies IncRobotics TrendsWind RiverYaskawa Motoman Robotics

MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

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LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

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NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 4: Modern Materials Handling - October 2010

Dematic Group a leading global supplier of integrated materials handling solu-tions and services has successfully completed the acquisition of HK Systems a North american automated materials handling and soft-ware solutions provider this strategic union was made final on Sept 15 2010

John K Baysore ceo of Dematic North america (wwwdematicus) will be responsible for leading and developing the newly combined company in the united States and canada With more

than 20 years of executive experience Baysore will lead Dematic in the design delivery and support of a more robust and diversified solution offering to the companyrsquos customers the newly combined company will be called Dematic with its North american headquarters in Grand rapids mich the expanded manufacturing foot-

print will allow Dematic to domestically manufacture automated storage and retrieval machines and automated guided vehicles in addition to conveyor sortation and order fulfillment technology

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 3

Lift trucK DiStriButor Barclay Brand ferdon is supporting National Breast cancer awareness month by raising money and awareness the distributor is displaying a pink painted Yale lift truck on its front lawn through the month of october and they plan to participate in the american cancer Societyrsquos ldquomaking Strides against Breast cancerrdquo walk in Woodbridge center (Woodbridge NJ) on oct 17

ldquoWe have pledged to match all of the donations made by our employeesrdquo said Skip russo president and ceo of Barclay Brand ferdon ldquoi am proud of the people

who work for Barclay although it has been a tough economy for all of us our employees have really stepped up to make a difference in our community Wersquove also had a great response from our vendors in support of this effortrdquo Barclay Brand ferdon is a distributor in New Jersey and New York for all warehousing equipment and support services

Pink lift truck supports breast cancer awareness month

1913the number of exhibiting companies at PaCK eXPo international oct 31 to Nov 3 at mccormick place in chicago

dematic group completes acquisition of HK systems

new player in the carousel market

FAST FACT

UP FRONT B r e a k i n g n e w s y o u s h o u l d k n o w

CeMa report says booked orders were down in July

a NeW proviDer Sapient automation is entering the market for vertical and horizontal carousels and vertical lift modules (vLms) according to ed romaine chief marketing officer for Sapient (wwwgetsapientcom) romaine announced the formation of the new company

at the fall meeting of the material Handling industry of america (mHia) in palm Springs calif the new com-pany is a subsidiary of mDci a pro-vider of industrial automation solu-

tions to the uS postal Service ldquoWe launched the company in Januaryrdquo romaine said ldquoand wersquove spent the last nine months ramping uprdquo While the company is a new player

romaine said Sapient has completed its first sale to an industrial facility in the healthcare industry

iN itS LateSt moNtHLY report the conveyor equipment manufacturers association (cema wwwcemanetorg) reported its July 2010 Booked orders index was 131 the index in July is down 36 points or 22 from June 2010rsquos index of 167 While down from June the July 2010 index represents an increase of 49 from the July 2009 index of 88

What does this mean Bob reinfried cemarsquos executive vice president said the conveyor industry had a very good month While down from June July 2010 was still better than July 2009 itrsquos too early to tell if numbers will continue to climb cema is forecasting an increase of 2 to 3 for the North american conveyor market in 2010

Baysore

MMH1010_Upfrontindd 3 101210 158 PM

wwwhyundai-cecom

Beyond the LimitsHyundairsquos cutting-edge technology is the new criteria of

forklift trucks

HEAD OFFICE(REP of KOREA) Tel 82 2 746 4526 Fax 82 2 746 7444~5 E-mail jcjunghhicokr wwwhyundai-cecom

HCE AMERICAS(USA) Tel 1 847 437 3333 Fax 1 847 437 3574 wwwhceamericascom HHI EUROPE(BELGIUM) Tel 32 14 56 2200 Fax 32 14 59 3405~6 wwwhyundaieu HHI BEIJING(CHINA) Tel 86 10 8321 3377 Fax 86 10 5143 8502 wwwhyundai-bjcom

DUBAI BRANCH OFFICE(UAE) Tel 971 4 425 7995 Fax 971 4 425 7996 E-mail sbyunhhicokr

ISTANBUL BRANCH OFFICE(TURKEY) Tel 90 212 345 1261~2 Fax 90 212 345 1263 E-mail eunsoohhicokr

MOSCOW BRANCH OFFICE(RUSSIA) Tel 7 495 258 1381 Fax 7 495 258 1382 E-mail leokanghhicokr

FORKLIFT LINE-UP

LPG Forklift 15 - 45Ton Battery Forklift (Counter Balanced) 16 - 5Ton

Reach Truck (Seated) 14 - 25TonReach Truck (Standing) 1 - 25Ton Electric Towing Platform Truck40TA-715PA-7

Diesel Forklift 15 - 18Ton

MMH1010_Adsindd 4 101210 1053 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 5

PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION WAREHOUSING AND MANUFACTURING

VOL 65 NO 10

DEPARTMENTS amp COLUMNS 3 Upfront 7 This Month in Modern16 Lift Truck Tips Level the playing field38 Focus On Palletizers42 Supplement WarehousesDCs50 60 seconds with

NEWS 9 MHIA Growth is back 9 HighJump to acquire TrueCommerce10 Final thoughts on Supply Chain Reset13 Industrial real estate market making

progress challenges remain

14 Crown unveils 20 electric lift trucks to operate with fuel cells

COVER STORYSYSTEM REPORT

18 Best in classDel Monte Foodsrsquo new Topeka DC brings laser-guided AGVs from manufacturing into distribution The result is a best-in-class materials handling system that minimizes costs with room to expand in the future

22 Automatic guided vehicles streamline operationsLaser-guided AGVs move product from the manufacturing plant and through the distribution center

FEATURESPRODUCTIVITY SOLUTION

25 Tilt toward safety and productivityAluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

SPECIAL REPORT

26 Top 20 automatic data capture suppliersThe ADC market took a significant hit in 2009 but the recovery may already be underway

INFORMATION MANAGEMENT

30 In sync Data capture and mobile computing Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

EQUIPMENT REPORT

34 Carousels Turning picking into productivityNot just for high-density storage anymore todayrsquos carousels are delivering product to the person while increasing productivity reducing labor saving space and cutting energy costs

60 seconds with Joan Barrett Kellogg p 50

Modern Materials Handling reg (ISSN 0026-8038) is published monthly by Peerless Media LLC a Division of EH Publishing Inc 111 Speen St Suite 200 Framingham MA 01701 Annual subscription rates for non-qualifi ed subscribers USA $119 Canada $159 Other International $249 Single copies are available for $2000 Send all subscription inquiries to Modern Materials Handling 111 Speen Street Suite 200 Framingham MA 01701 USA Periodicals postage paid at Framingham MA and additional mailing offi ces POSTMASTER Send address changes to Modern Materials Handling PO Box 1496 Framingham MA 01701-1496 Reproduction of this magazine in whole or part without written permis-sion of the publisher is prohibited All rights reserved (C)2010 Peerless Media LLC

reg

PHOTO BLAINE FISHERGETTY IMAGES

Keith Arntson and his team at Del Monte put a fl eet of laser-guided AGVs to work at their DC

handling system that minimizes costs with room to expand in the future

60 seconds with Joan Barrett Kellogg p 50

BLAINE FISHERGETTY IMAGES

MMH1010_TOCindd 5 101310 947 AM

Introducing the new Automatic Destratification System

Big Ass Fans have always saved money in the winter but now it can be done with the push of a button The patent pending Automatic Destratification System keeps your space at the perfect temperature year-round from floor to ceiling The Automatic Destratification System calculates the floor-to-ceiling temperature differential and modulates the fanrsquos speed so you donrsquot have to

Bottom line you could save up to 30 on your heating bills this winterhellip and next winterhellip and next winterhellip

pending Automatic Destratification System keeps your space

Bottom line you could save up to 30 on your heating bills

NEWNEWNEW

Visit wwwBigAssFanscom or call 877-BIG FANS (877-244-3267) to learn moreAn ISO 90012008 certified company

If global warming doesnrsquot reduce your energy costs this winter perhaps we can help

Covered by one or more of the following US Patents 6244821 6589016 6817835 6939108 7252478 7284960 7654798 D587799 D607988 and other patents pending

10 year parts 1 year labor warranty certain exclusions apply See complete warranty for details copy 2010 Delta T Corporation dba The Big Ass Fan Company All rights reserved

BAF_MMH_DestratAd_091610indd 1 91710 851 AMMMH1010_Adsindd 6 101210 1053 AM

EDITORIAL OFFICES111 Speen Street Suite 200Framingham MA 01701-1496(800) 375-8015

Michael LevansGROUP EDITORIAL DIRECTOR mlevansehpubcom

Bob TrebilcockEXECUTIVE EDITOR

roberttrebilcockmyfairpointnet

Noeumll P BodenburgEXECUTIVE MANAGING EDITOR

nbodenburgehpubcom

Lorie King RogersASSOCIATE EDITOR

lrogersehpubcom

Sara Pearson SpecterEDITOR AT LARGE

saramoxiemarketingllccom

Roberto MichelEDITOR AT LARGE

robertomichelnewrrcom

Tom AndelCOLUMNIST

tandel4315aolcom

Jeff BermanGROUP NEWS EDITOR

jbermanehpubcom

Josh BondCONTRIBUTING EDITOR

turbobondgmailcom

Mike RoachCREATIVE DIRECTOR

mroachehpubcom

Wendy DelCampoART DIRECTOR

wdelcampoehpubcom

Daniel GuideraILLUSTRATION

danieldanielguideracom

Brian CeraoloGROUP PUBLISHER bceraoloehpubcom

EDITORIAL ADVISORY BOARD

Ron Giuntini OEM PRODUCT-SERVICES INSTITUTE

John HillESYNC

TRANSYSTEMS

Susan RiderRIDER amp ASSOCIATES

Ken RuehrdanzDEMATIC

Dr John Usher UNIVERSITY OF LOUISVILLE

Col Alan B Will2D MARINE LOGISTICS GROUP

Brett WoodTOYOTA MATERIAL HANDLING USA

Peerless Media LLCA DIVISION OF EH PUBLISHING INC

Kenneth MoyesPRESIDENT AND CEOEH PUBLISHING INC

Brian CeraoloPUBLISHER AND EXECUTIVE VICE PRESIDENT

PEERLESS MEDIA LLC

MAGAZINE SUBSCRIPTIONSStart renew or update your FREE magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPhone 1-800-315-1578Mail Peerless Media PO Box 1496 Framingham MA 01701

eNEWSLETTER SUBSCRIPTIONSSign up or manage your FREE eNewsletter subscriptions at wwwmmhcomenewsletters

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 7

reg

Member Member ofOfficial Publication of

Winner Jesse H Neal

Certificates of Merit for Journalistic

Excellence

EDITORIAL OFFICES111 Speen Street Suite 200Framingham MA 01701-1496(800) 375-8015

Michael LevansGROUP EDITORIAL DIRECTOR mlevansehpubcom

Bob TrebilcockEXECUTIVE EDITOR

roberttrebilcockmyfairpointnet

Noeumll P BodenburgEXECUTIVE MANAGING EDITOR

nbodenburgehpubcom

Lorie King RogersASSOCIATE EDITOR

lrogersehpubcom

Jeff BermanGROUP NEWS EDITOR

jbermanehpubcom

Sara Pearson SpecterEDITOR AT LARGE

saramoxiemarketingllccom

Roberto MichelEDITOR AT LARGE

robertomichelnewrrcom

Josh BondCONTRIBUTING EDITOR

turbobondgmailcom

Mike RoachCREATIVE DIRECTOR

mroachehpubcom

Wendy DelCampoART DIRECTOR

wdelcampoehpubcom

Daniel GuideraILLUSTRATION

danieldanielguideracom

Brian CeraoloGROUP PUBLISHER bceraoloehpubcom

EDITORIAL ADVISORY BOARD

Ron Giuntini OEM PRODUCT-SERVICES INSTITUTE

John HillESYNC

TRANSYSTEMS

Susan RiderRIDER amp ASSOCIATES

Ken RuehrdanzDEMATIC

Dr John Usher UNIVERSITY OF LOUISVILLE

Col Alan B Will2D MARINE LOGISTICS GROUP

Brett WoodTOYOTA MATERIAL HANDLING USA

Peerless Media LLCA DIVISION OF EH PUBLISHING INC

Kenneth MoyesPRESIDENT AND CEOEH PUBLISHING INC

Brian CeraoloPUBLISHER AND EXECUTIVE VICE PRESIDENT

PEERLESS MEDIA LLC

MAGAZINE SUBSCRIPTIONSStart renew or update your FREE magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPhone 1-800-315-1578Mail Peerless Media PO Box 1496 Framingham MA 01701

eNEWSLETTER SUBSCRIPTIONSSign up or manage your FREE eNewsletter subscriptions at wwwmmhcomenewsletters

MICHAEL LEVANSGROUP EDITORIAL

DIRECTOR

THIS MONTH IN MODERN

While it may be at a much slower pace than predicted growth is actually taking place whether

yoursquore feeling it or not In fact we kick off this monthrsquos issue with the latest report from the Material Handling Industry of America that forecasts equipment orders to grow 12 to 14 in 2010 if the current momen-tum persists (page 9)

Mind you those new numbers are com-ing off 2009 when orders saw a 343 de-cline from 2008 But any way we position the latest forecast we canrsquot help but see it as positive news for the industry overall It may even help to crack a few smiles

But while numbers donrsquot lie they can of-ten be deceiving Even though it appeared that equipment orders fell off a cliff two years ago that didnrsquot mean that materials handling professionals went into hiberna-tion in terms of executing improvement projects

In his thoughtful wrap up of HK Systemsrsquos recent Material Handling and Logistics Con-ference (page 10) executive editor Bob Tre-bilcock recounts a number of conversations that he had with attendees who were eager to share the details of the projects that they completed over the past 18 months or moved to the front burner over the past six months There was a local authority looking to put in a new ASRS the Federal Reserve Bank was investigating storage systems and even a specialty foods manufacturer looking to expand a fl eet of AGVs

ldquoI donrsquot think companies plan multi-million dollar investments in automation if

they think the apocalypse is right around the cornerrdquo observes Trebilcock

My fi rm belief that innovation never goes out of stylemdashno matter what the economic environment may bemdashhas been further validated in the system reports that have graced Modernrsquos covers over the past two years Offi ce Depot Kroger Crate amp Barrel Patagonia Bon-Ton Stores The Ap-parel Group IKEAhellipand the list goes on Each of these innovation mavericks has put precious time and strategic thought into materials handling projects that will put them in a distinct competitive advantage as the economic fog begins to clear

Itrsquos safe to say that the brutal economy never once stopped Keith Arntson vice president of distribution operations for Del Monte Foods from thinking how to he could help take miles out of the food giantrsquos distribution network by applying a few new innovations inside his To-peka Kan DC In fact after reading this monthrsquos System Report (page 18) you can say that Arntson has fl ipped over a few materials handling axioms en route to a stunning success

This month Irsquom going to leave Modern readers with a challenge After reading the Del Monte success story Irsquod like you to share with us a few of the innovation projects that yoursquove conducted during the past 18 months We believe that innovation never goes out of style now help us spread the good word and inspire a few of the late adopters Please send me an email on your better idea(s) mlevansehpubcom

Innovation never goes out of style

MMH1010_Editorialindd 7 101310 254 PM

Modern Materials Logistics Management Supply Chain Management

bull Automation

bull Conveyors amp Sorters

bull Inventory amp Picking

bull Loading Dock Equipment

bull Mobile amp Wireless

bull Shipping Pallets

bull Storage Systems

bull Containers amp Totes

bull Energy amp Sustainability

bull Lift Truck amp Fork Lift

bull Handling amp Warehouse Ergonomics

bull Packaging

bull Software amp Technology

wwwmmhcomcriticaltopics

Critical Industry News at Your Fingertips

Critical Topic areas help you develop strategies and expand your knowledge Each topic provides you with the news information and resources you need mdash each day

CRITICAL TOPICS

Modern Materials Logistics Management Supply Chain Management

MMH_CriticalTopics_Houseindd 1 81010 117 PMMMH1010_Adsindd 8 101210 1053 AM

ITrsquoS STILL A FAR CRY FROM 2007 but the materials handling industry is growing once again Following a 343 decline in equipment orders in 2009 the Material Handling Industry of America (MHIA wwwmhiaorg) is forecasting equipment orders to grow 12 to 14 in 2010 if the current momentum continues

A variety of factors are driving growth in manufacturing warehous-ing and distribution on a global basis especially an increase in industrial pro-duction in the fi rst half of 2010 despite factory utilization rates that remain very low by historical comparison

ldquoConsumer demand has not returnedrdquo Hal Vandiver executive vice president of business develop-ment for MHIA told Modern during the associationrsquos fall meeting ldquoBut in the fi rst two quarters the economy shifted from recession into recovery mode fi lling supply chain pipelines re-establishing inventories and re-sponding to pent up demandrdquo

While Vandiver expects the indus-try to continue to grow by 11 to 12 in 2011 drags on the economy continue ldquoForecasts are now calling for a combination of reduced GDP corporate profi t business investment and output growth with industrial utilization remaining below 75 until

late 2011rdquo Vandiver said ldquoThis is largely due to uncertainty Consumers inves-tors and business owners need greater confi dence in the economyrsquos ability to sustain positive growthrdquo For those reasons Vandiver doesnrsquot expect a signifi cant return to the kinds of num-bers the industry posted in the past up until 2007

In addition to

a growth in orders for new equipment Van-diver forecasts material handling shipments to grow 3 to 4 in 2010 and another 10 to 11 in 2011 Domestic demand defi ned as shipments plus imports less exports will grow by 1 in 2010 and by 10 to 11 in 2011 Exports will be stronger than im-ports in 2010 and 2011 refl ecting stronger indus-trial growth in emerging markets outside North America

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 9

Company Briefi ngs | Bob Trebilcock

The age of automationExpressed as an equation The industrial age + the information age = the automation age

mmhcomblogsautomation

Diblogbest of Modernrsquos blogs

BY BOB TREBILCOCK EXECUTIVE EDITOR

ECONOMY

MHIA Growth is backMHIA FORECASTS 12 TO 14 GROWTH IN NEW EQUIPMENT ORDERS IN 2010

0

-343

2009 2010

130(forecast)

MHIA equipment orders forecast

Source Material Handling Industry of America (MHIA)

HIGHJUMP SOFTWARE announced today that it has reached agreement to acquire TrueCommerce a provider of business-to-business integration solutions TrueCommerce provides a comprehensive end-to-end suite of trading partner connectivity solutions including electronic data interchange (EDI) translation and data mapping software transaction network and on-boarding services HighJump Software (wwwhighjumpcom) ranks

No 11 on Modernrsquos 2010 Supply Chain Management Software an-nual list with $85 million in revenue TrueCommercersquos solutions enable trading partner connectivity for 3000 customers feature predefi ned inte-gration to many major ERP systems and can be deployed in either SaaS or on-premise models

The TrueCommerce trading part-ner integration solution complements HighJump Softwarersquos existing supply

MampA

HighJump to acquire TrueCommerce

mmh1010_newsindd 9 101310 1049 AM

middot Robotic palletizing cells handle goods at the end of the production linemiddot LGVs transport pallets to stretch wrapping and labelingmiddot LGVs transport finished pallets to the warehousemiddot LGVs for Storage amp Retrieval (SRS)middot LGVs for Auto-Trailer Loading (ATL)middot An integrated software management system

Elettric 80 is a global provider of end-of-lineautomation solutions These solutions are called Freewayreg material handling system

The technologies are adaptable and have a high degree of built-in flexibility which makes them suitable for any plant warehouse layout or design More details explanatory videos and animations can be found at wwwelettric80com

ITALY middot USA middot SWEDEN middot UK middot AUSTRALIA middot POLAND

Elettric 80 Inc8100 Monticello AvenueSkokie IL 60076 USAPhone +1 847 329 7717e80usaelettric80it

Freewayreg is based on a simple idea

C

M

Y

CM

MY

CY

CMY

K

el80_US_verticalpdf 1 2010-09-29 1346

chain application suite which spans from supplier to store shelf and includes warehouse management systems transportation management systems route accounting systems manufacturing execution mobile sales and ERP data collection Trading partner collaboration is increas-ingly important as organizations strive to reduce costs and improve service levels By combining integration solutions with application functionality organizations are able to ensure consistency in business processes and accuracy of information exchanged with trading partners

ldquoTrueCommerce has fi lled a unique need in the market for simple robust and affordable EDI solutions for small and midsized businessesrdquo said Nick Manolis TrueCom-merce CEO ldquoI am excited for the TrueCommerce team to join HighJump while continuing to provide excellent service support and product innovation to our customersrdquo

ldquoCombining HighJump and TrueCommerce creates a unique and compelling solution offering within the supply chain software marketrdquo said Russell Fleischer HighJump Software CEO ldquoOur view is that supply chain applications must allow users to connect with a broad ecosystem of trading partners to maximize value The TrueCommerce solution platform and our previous move to cloud-based applications will help translate this vision into reality for our customersrdquo

SUPPLY CHAIN NEWS ANALYSIS

Final thoughts on Supply Chain Reset conferenceBY BOB TREBILCOCK EXECUTIVE EDITOR

DESPITE SIGNS OF IMPROVEMENTS doing business in in materials handling remains a challenge At the same time many of the leading customers are investing in supply chain software and automated materials handling systems to improve their businesses That suggests better times are coming

Tom Brokaw punctuates the 25th anniversary of the Material

Handling and Logistics Conference by HK Systems

mmh1010_newsindd 10 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 11

Leader of the PackThe originator of high speed narrow belt sortationTGW Systems has led the way in offering provenadvantages over conventional sortation for over 10 years

NBS fromTGW Systems

50 less install time60 less energy75 less noise

100 of the Value

wwwtgw-groupcom

TGW Systems (formerly TGW-Ermanco) is an integrated logistics solutions and material handling equipment provider The Ermanco name lives onas the product family name for the conveying andsortation products manufactured in the US

Our worldwide perspective and resources and commitment to innovation product developmentand unparalleled customer service can help you today

Proven track record ndash Over 700 installations around the world have made TGWrsquos Narrow Belt Sorter one of the most reliable sorters available

Rugged durability ndash TGWrsquos NBS sorters operate in some of the harshest distribution environments in the world earning customerrsquos admiration and competitorrsquos respect

Application and layout fl exibility ndash The universal frame on TGWrsquos narrow belt sorter means you can use multiple divert options and easily add divert modules after installation for increased fl exibility

Patented technology ndash Patented sortation technology in the TGWrsquos narrow belt sorter continues to lead the way in effective energy effi cient fl exible sortation

10 08 NBSindd 1 8302010 34008 PM

keep enough labor to run his primary distribution center Two presentations drove this point home The fi rst was from an executive with Tim Hor-tons the Dunkin Donuts of Canada The companyrsquos beautiful new DC in Guelph Ontario is underperforming projections even though the ASRS is

living up to its promises The reason The company canrsquot fi nd enough labor willing to work in its case picking and palletizing operations The other was by Terra Winston a consultant who presented a case study about a proj-ect at PepsiCo to develop the next wave of supply chain leaders Her

Those are the two high level take-aways from Supply Chain Reset the annual logistics conference held last month in Park City Utah sponsored by HK Systems now part of Dematic

ldquoLousyrdquo was the most common response to the dinner-time question ldquoHowrsquos businessrdquo

At the same time the roll call of end user companies that said they had projects in the works or on the drawing board was both a Whorsquos Who of American business with names like Coca-Cola and Kraft and companies many of us may never have heard of or think of as custom-ers of our solutions For example I sat on the van from the airport with a guy from the Los Angeles metro-politan transportation system looking for a new automated storage and retrieval system (ASRS) The Federal Reserve Bank was there investigat-ing storage systems I rode in the van back to the airport with a woman from a producer of honey in Texas who had both an ASRS and auto-matic guided vehicles in her facil-ity and was looking to expand her system

Those are signs of a growing con-fi dence I donrsquot think companies plan multi-million dollar investments in au-tomation if they think the apocalypse is right around the corner

One other anecdotal data point Marc Ducharme a vice president and partner with Axium a supplier of robotic materials handling solu-tions told me that 2009 was a dismal year for implementations but that his company has been swamped with RFPs in 2010 An RFP is not an order but itrsquos a sign

A few other observationsRetaining labor and talent could

be the most important issue facing the industry in the future A week or so before going to Utah I had a con-versation with a vice president of sup-ply chain for a major retailer who told me he is interested in automation because he simply cannot fi nd and

mmh1010_newsindd 11 101310 1049 AM

12 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

point the talent shortage isnrsquot limited just to the shop fl oor

Retrofi tting is a viable solution You know the old saying Every-thing old is new again Wegmanrsquos a Midwestern grocer and Rubber-maid both gave strong presenta-tions about how they replaced ag-ing ASRS cranes to breathe new life into their DCs Meanwhile Anheuser Busch gained new ef-fi ciencies in its Columbus Ohio facility by upgrading a warehouse control system

Everyone loves pallets Based in Iowa Green Line Armor is offering a heavy-duty hybrid woodplastic pallet for permanent pallet pools The 48- x 40-inch pallet has heavier stringers and more deck board coverage than a grocery pallet The lead boards on the top and the bottom of the palletmdashthose most likely to get damaged by a lift truckmdashare manufactured from heavy plastic The pallet has a passive RFID

tag that is used by Green Line Armor to identify the pallet and manage war-ranty services Active RFID tags were installed for John Deere the companyrsquos largest customer to track the location of work in process stored on the pallets between manufacturing processes Eric Renteria the companyrsquos president said the pallets which come with a 10-year warranty can be purchased or leased

in a pooling modelNew players are get-

ting into automation Kip Tygard whose company makes the Tygard Claw a lift truck attachment for mixed case palletizing is investing RampD money to develop an automated version of the Claw Thatrsquos not a big shock Tygard is an OEM But I also had conversations with two very large end users in the wholesale food distribu-

tion business that have designed their own automated systemsmdashone has built and implemented its own ASRS design for freezers for years the other has designed its own case picking application that it intends to put out for bid to the materials handling community Both say they may commercialize their solutions in the future

VERSATILITY MATTERSQuality Wildeck construction and versatility make the V-lifttrade the ultimate lifting solution

In todayrsquos lsquogreenrsquo building designs floor space is at a premium and moving up not out is definitely preferred Look no further than the V-Lifttrade from Wildeck ndash the industry leader in space optimization The single cylinder hydraulic system eliminates all moving hoses cables and chains Fewer components means easy installation reduced maintenance and longer service life To get more value out of your operation contact a Wildeck representative today

copyWildeck Inc 2010 Required safety gates and guarding removed for clarity

800-325-6939 | WWWWILDECKCOM

MEZZANINESCapacity Matters Efficiency Matters

LIFT SYSTEMSSafety MattersGUARDING PRODUCTS

able to make better decisionsmdashespecially in the case of the unexpected ldquoWhen a shipment is held up at the portrdquo says Prashant Bhatia director of solutions management at SAP ldquoit can trigger logic back to say that Irsquove got a problem I can no longer allocate that inventory on that particular shipment as I thought I couldrdquo

3 One database one system one supply chain In the last few years soft-ware providers have been pulling all of their products onto a single supply chain process platform ldquoItrsquos fairly newrdquo says Lamphier ldquoVarious components have been integrated into that supply chain process platform longer than others but actually moving our WMS onto it has been a more recent developmentmdashjust within the last quarter or twordquo

SAP uses its enterprise resource planning (ERP) system as the central repository of information of supply and demand as well as inventory for the entire supply chain And the modules all

talk to each other Transportation man-agement systems (TMS) in conjunction with the event management modules help optimize freight determine pick-up windows determine carriers keep track of in-transit times and create ASNs

That ASN not only gets sent back to the ERP for visibility but it also gets sent to the WMS where the sys-tem uses the information to plan labor equipment and resources at the receiv-ing dock When the physical product arrives logic within the WMS based on the receipt of goods determines matches against actual demand

Smarter speedier equipment With more retailers crossdocking

over 50 of their items at the case level to their stores equipment innovations have centered on conveyor sortation systems print and apply mechanisms and automatic identifi cation technolo-gies Here are three new equipment

advances1 Smaller gaps and self-regulat-

ing conveyors In the last year the sliding shoe sorter has undergone note-worthy transformations ldquoBy doing a par-allel divert we can now run the packages closer together and get a higher through-put on the same systemrdquo reports Ken Ruehrdanz manager for Dematicrsquos distri-bution and warehousing markets

The sliding shoes that used to physi-cally push the cartons off the sorter at an angle can now run those shoes in parallel enabling smaller gaps between cartonsmdashwhich were previously from 6 inches to 8 inchesmdashdown to 3 inches

With more dense traffi c on conveyors crossdock operators can run their con-veyors at a lower speed while still achiev-ing the same throughput Slower speeds equal less wear and tear decreased energy usage and less maintenance

Another conveyor breakthrough is automatic speed control ldquoThe whole

m m h c o m MODERN MATERIALS HANDLING A P R I L 2 0 1 0 49S

MMH100401sup_Crossdock_ID 49 482010 113620 AM

Leading customers are investing in software and automated

systems to improve business according to attendees of the

Supply Chain Reset conference

mmh1010_newsindd 12 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 13

THE INDUSTRIAL REAL ESTATEmarket is taking steps in the right direction according to a report recently issued by global real estate fi rm Jones Lang LaSalle (JLL wwwjoneslanglasallecom) which report-ed the national average vacancy rate for the North American industrial real estate sector fell from 106 in the fi rst quarter to 104 in the second quarter Despite the slight decline in vacancy the fragile economy still looms large due to declining con-sumer confi dence the drying up of economic stimulus funding and the potential threat of a double-dip recession the report noted

ldquoWe have seen a positive absorp-tion in the vacancy rate in the second quarter but we are very concerned

going forwardrdquo Craig Meyer managing director and leader of JLLrsquos Logistics and Industrial Services Group told Modern ldquoAny kind of sustained demand-driven component in the industrial real estate market is going to be driven by jobs We are just not seeing any of that It is going to be a long slow recoveryrdquo

Looking at base indicators like the Institute of Supply Managementrsquos Manufacturing Index Consumer Confi dence data and industrial real estate vacancy and absorption rates there does not appear to be what Meyer labeled as a strong indication of a positive upswing on the horizon

The report says that a need to restock inventories that were running at 50-year lows resulted in large com-panies strategically capturing high

quality logistics space at cyclically low rates And with slow levels of leasing activity and sparse construc-tion industrial real estate optionsmdashespecially in the Class A large block sectormdashare limited in some markets

And the swift correction in invento-ries during the second half of 2009 and fi rst quarter of 2010 has left inventory levels lean and ready for expansion provided sales rebound in the coming months Should this occur it could lead to increased industrial and logistics real estate leasing activity

The report also pointed out that the initial recovery in the economy was largely driven by improvements in the manufacturing sector and cyclical adjustments in inventories But with the recovery now becoming more broad-based the recent slowdown of inven-tory building could have more of an impact on the industrial property sector than the offi ce sector the report noted

Date 090910 Client Rehrig Pacifi c Job 08312010 File Name 0831_RPC_SlipSheet_Ad_MMH_Oct10 Round

Account Director Niki Phan Designer Revised By ov Editor Production ov

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Publication(s) TBD Run Date(s) TBD

Approved By

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Available in standard or custom sizes with a variety of surface textures and embossed patterns Rehrig Slip Sheets provide superior slide resistance keeping goods securely in place Manufactured from nearly 100 recycled material each sheet is also 100 recyclable

Beyond the sale Rehrig can help you develop a customized re-use or buy-back program further lowering your average cost per trip

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Industrial real estate market making progress challenges remain

mmh1010_newsindd 13 101310 1049 AM

14 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

ldquoWe are also concerned about seasonality with the holiday season coming uprdquo said Meyer ldquoThe indica-tions we are getting are that we may not see as much preparation for that as we hoped A lot of retailers are saying they are restocked and if consumer confi dence is going down they are not going to build up inventories And for larger big box companies they will see declining values in rents but the availability of product for them to lease is diminishingrdquo

As a result Class A big box dis-tribution space is becoming more diffi cult to fi nd in this economy said Meyer But the build-to-suit market could come back for major retailers as evidenced by a new 1-million-square-foot DC space deal by Amazoncom in Harrisburg Pa and a 14-million-square-foot location in Phoenix

But for a mid-sized industrial building in the 100000-to-150000-square-foot range Class B-sized build-

ing Meyer said there are an infi nite number of these on the market

Looking ahead Meyer said there will still be downward pressure on pric-

ing a double-digit vacancy rate and no increases in lease rates which he noted are actually weakening a little bit and tend to lag a recovery

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BFL AD MMH APRIL 92710 358 PM Page 1

CROWN EQUIPMENT Corp has quali-fi ed 20 of its electric models to operate with various fuel cells bringing the total of qualifi ed combinations of fuel cell packs and trucks to 29 In 2009 Crown (wwwcrowncom) was the fi rst lift truck manufacturer to introduce a fuel cell qualifi cation program

Eric Jensen Crownrsquos manager of new technology research and de-velopment told Modern that the companyrsquos fuel cell qualifi cation pro-gram duplicates its own testing and is conducted at a 25000-square-foot research facility near Dayton Ohio Through the testing process engi-

neers evaluate fuel cell performance and monitor whether issues develop that affect the truckrsquos operation

To qualify a fuel cell pack and truck combination Crownrsquos engineers review key performance metrics for a battery-powered truck such as traction plug-ging and lift and travel speeds Then they replace the battery with a fuel cell power pack and measure the same indicators Through modeling and ap-plication testing the research team de-termines design modifi cations needed to ensure the fuel cell-powered forklift matched standards to which the truck was designed

LIFT TRUCKS

Crown unveils 20 electric lift trucks to operate with fuel cells

mmh1010_newsindd 14 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 15

ldquoWersquove been steadfast in our posi-tion that deployment of a fuel cell forklift fl eet must be carefully evalu-ated and tested for appropriate use in a warehouserdquo said Jensen ldquoThis research-based approach means that our customers can confi dently know they have the right truck for their chosen fuel cell allowing them to meet their performance safety and

environmental sus-tainability goalsrdquo

Crown continues to work closely with fuel cell manufactur-ers and customers to qualify trucks as new fuel cell pack models are intro-duced ldquoForklifts are a key early market for fuel cellsrdquo said Lisa Callaghan Jerram senior market analyst for Fuel Cell Today a leading analyst

fi rm providing market-based research on the fuel cell industry ldquoBased on our market research we have found strong growth in this sector in the past three yearsrdquo

Because fuel cell powered electric forklifts give off exhaust in the form of moist warm air IC truck custom-ers are looking to this technology

so they donrsquot have to deal exhaust issues Jensen said Another advan-tage pointed out by Jensen is a fuel cell powered truckrsquos ability to effec-tively operate in a cold environment because they generate their own heat and the power doesnrsquot fall off like a traditional battery

While the upfront hardware cost of fuel cells is more expensive than a traditional battery Jensen pointed out the potential to capture savings in labor battery changes battery rooms and heating and venting With fuel cells he said a facility doesnrsquot need a battery room and all that goes in to running it properly Instead there is an ongoing savings associated to using fl oor space for production or other value-added operations

ldquoFuel cells have always been talked about fi ve years into the future but we have customers who are [currently] planning installations around this prod-uctrdquo said Jensen ldquoThe future is hererdquo

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To qualify a fuel cell pack and truck combination engineers

review key performance metrics

mmh1010_newsindd 15 101310 1049 AM

lift truck TIPS

GraphicCaption

In the right application tuggers and carts can be a fast and efficient solution

Level the playing field

Football season is under-way and fans are hoping for breakout performances

from stars and rookies alike On the gridiron an overpowered player can be a distinct advan-tage In the warehouse how-ever too much power can lead to waste danger and sluggish performance For some corpo-rations this fact has prompted consideration of fork-free envi-ronments where versatile and custom-built carts and tuggers can do the work faster and more efficiently than their big-ger cousins

Disposing of expensive and powerful equipment in favor of carts may seem counter-intuitive but Jill Burrow marketing manager for Topper Industrial says certain warehouses might benefit greatly from the switch For operations requiring multiple trips between the same areas carts can cut travel time sig-nificantly According to Ed Brown president of Topper Industrial a tugger can pull as many as 13 carts In addi-tion says Brown carts and tuggers can be easier to use than many forklifts

ldquoA forklift costs five times as much but a forklift opera-tor also costs five times more than a tugger operatorrdquo says Brown ldquoAnyone can grab a tugger and gordquo

Once a forklift drops off a pallet in many cases a picker must bend to access product or arrange for the pallet to be lifted Carts on the other hand can be configured with swiveling or angled platforms to allow pickers fast and comfortable access to products Worker safety issues tied to forklifts that operate in tight areas such as poor visibility when driving in re-verse and dock mishaps can also be greatly reduced

ldquoCompanies looking at carts are looking at the cost of equipment and the cost of maintenance but theyrsquore also looking at safetyrdquo says Brown

In addition to ergonomics and safety a fork-free zone might help a warehouse reduce product loss and equip-ment damage Carts provide a secure cradle for moving product while some fork-borne loads are prone to top-pling And forklifts often 10 times as heavy as a tugger and cart setup have a way of proving their strength by leaving dings and dents on storage racks and other hap-less stationary objects

With carts and tuggers Brown says most companies see a return on investment within a year In football a first-round draft pick can cost millions over a multi-year contract before he produces the desired results For com-panies not looking to attempt such a Hail Mary tuggers could prove an efficient alternative

Josh Bond is a contributing editor to Modern and can be reached at turbobondgmailcom

16 O c t O b e r 2 0 1 0 Modern Materials Handling m m h c o m

lift truck TIPS

By Josh Bond Contributing Editor

MMH1010_LiftTruckTipsindd 16 101310 942 AM

MM100601Adsindd 3 6310 349 PMMMH1010_Adsindd 17 101210 1053 AM

18 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

Keith arntson vice president of distribution operations for

del Monte Foods

Four conveyor-topped vehicles ferry loads from an adjacent manufacturing plant

MMH1010_SystemRptDelMonteindd 18 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

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Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

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From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

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MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

chepcomsimplechoice

Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

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46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

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New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

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Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

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  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 5: Modern Materials Handling - October 2010

wwwhyundai-cecom

Beyond the LimitsHyundairsquos cutting-edge technology is the new criteria of

forklift trucks

HEAD OFFICE(REP of KOREA) Tel 82 2 746 4526 Fax 82 2 746 7444~5 E-mail jcjunghhicokr wwwhyundai-cecom

HCE AMERICAS(USA) Tel 1 847 437 3333 Fax 1 847 437 3574 wwwhceamericascom HHI EUROPE(BELGIUM) Tel 32 14 56 2200 Fax 32 14 59 3405~6 wwwhyundaieu HHI BEIJING(CHINA) Tel 86 10 8321 3377 Fax 86 10 5143 8502 wwwhyundai-bjcom

DUBAI BRANCH OFFICE(UAE) Tel 971 4 425 7995 Fax 971 4 425 7996 E-mail sbyunhhicokr

ISTANBUL BRANCH OFFICE(TURKEY) Tel 90 212 345 1261~2 Fax 90 212 345 1263 E-mail eunsoohhicokr

MOSCOW BRANCH OFFICE(RUSSIA) Tel 7 495 258 1381 Fax 7 495 258 1382 E-mail leokanghhicokr

FORKLIFT LINE-UP

LPG Forklift 15 - 45Ton Battery Forklift (Counter Balanced) 16 - 5Ton

Reach Truck (Seated) 14 - 25TonReach Truck (Standing) 1 - 25Ton Electric Towing Platform Truck40TA-715PA-7

Diesel Forklift 15 - 18Ton

MMH1010_Adsindd 4 101210 1053 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 5

PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION WAREHOUSING AND MANUFACTURING

VOL 65 NO 10

DEPARTMENTS amp COLUMNS 3 Upfront 7 This Month in Modern16 Lift Truck Tips Level the playing field38 Focus On Palletizers42 Supplement WarehousesDCs50 60 seconds with

NEWS 9 MHIA Growth is back 9 HighJump to acquire TrueCommerce10 Final thoughts on Supply Chain Reset13 Industrial real estate market making

progress challenges remain

14 Crown unveils 20 electric lift trucks to operate with fuel cells

COVER STORYSYSTEM REPORT

18 Best in classDel Monte Foodsrsquo new Topeka DC brings laser-guided AGVs from manufacturing into distribution The result is a best-in-class materials handling system that minimizes costs with room to expand in the future

22 Automatic guided vehicles streamline operationsLaser-guided AGVs move product from the manufacturing plant and through the distribution center

FEATURESPRODUCTIVITY SOLUTION

25 Tilt toward safety and productivityAluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

SPECIAL REPORT

26 Top 20 automatic data capture suppliersThe ADC market took a significant hit in 2009 but the recovery may already be underway

INFORMATION MANAGEMENT

30 In sync Data capture and mobile computing Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

EQUIPMENT REPORT

34 Carousels Turning picking into productivityNot just for high-density storage anymore todayrsquos carousels are delivering product to the person while increasing productivity reducing labor saving space and cutting energy costs

60 seconds with Joan Barrett Kellogg p 50

Modern Materials Handling reg (ISSN 0026-8038) is published monthly by Peerless Media LLC a Division of EH Publishing Inc 111 Speen St Suite 200 Framingham MA 01701 Annual subscription rates for non-qualifi ed subscribers USA $119 Canada $159 Other International $249 Single copies are available for $2000 Send all subscription inquiries to Modern Materials Handling 111 Speen Street Suite 200 Framingham MA 01701 USA Periodicals postage paid at Framingham MA and additional mailing offi ces POSTMASTER Send address changes to Modern Materials Handling PO Box 1496 Framingham MA 01701-1496 Reproduction of this magazine in whole or part without written permis-sion of the publisher is prohibited All rights reserved (C)2010 Peerless Media LLC

reg

PHOTO BLAINE FISHERGETTY IMAGES

Keith Arntson and his team at Del Monte put a fl eet of laser-guided AGVs to work at their DC

handling system that minimizes costs with room to expand in the future

60 seconds with Joan Barrett Kellogg p 50

BLAINE FISHERGETTY IMAGES

MMH1010_TOCindd 5 101310 947 AM

Introducing the new Automatic Destratification System

Big Ass Fans have always saved money in the winter but now it can be done with the push of a button The patent pending Automatic Destratification System keeps your space at the perfect temperature year-round from floor to ceiling The Automatic Destratification System calculates the floor-to-ceiling temperature differential and modulates the fanrsquos speed so you donrsquot have to

Bottom line you could save up to 30 on your heating bills this winterhellip and next winterhellip and next winterhellip

pending Automatic Destratification System keeps your space

Bottom line you could save up to 30 on your heating bills

NEWNEWNEW

Visit wwwBigAssFanscom or call 877-BIG FANS (877-244-3267) to learn moreAn ISO 90012008 certified company

If global warming doesnrsquot reduce your energy costs this winter perhaps we can help

Covered by one or more of the following US Patents 6244821 6589016 6817835 6939108 7252478 7284960 7654798 D587799 D607988 and other patents pending

10 year parts 1 year labor warranty certain exclusions apply See complete warranty for details copy 2010 Delta T Corporation dba The Big Ass Fan Company All rights reserved

BAF_MMH_DestratAd_091610indd 1 91710 851 AMMMH1010_Adsindd 6 101210 1053 AM

EDITORIAL OFFICES111 Speen Street Suite 200Framingham MA 01701-1496(800) 375-8015

Michael LevansGROUP EDITORIAL DIRECTOR mlevansehpubcom

Bob TrebilcockEXECUTIVE EDITOR

roberttrebilcockmyfairpointnet

Noeumll P BodenburgEXECUTIVE MANAGING EDITOR

nbodenburgehpubcom

Lorie King RogersASSOCIATE EDITOR

lrogersehpubcom

Sara Pearson SpecterEDITOR AT LARGE

saramoxiemarketingllccom

Roberto MichelEDITOR AT LARGE

robertomichelnewrrcom

Tom AndelCOLUMNIST

tandel4315aolcom

Jeff BermanGROUP NEWS EDITOR

jbermanehpubcom

Josh BondCONTRIBUTING EDITOR

turbobondgmailcom

Mike RoachCREATIVE DIRECTOR

mroachehpubcom

Wendy DelCampoART DIRECTOR

wdelcampoehpubcom

Daniel GuideraILLUSTRATION

danieldanielguideracom

Brian CeraoloGROUP PUBLISHER bceraoloehpubcom

EDITORIAL ADVISORY BOARD

Ron Giuntini OEM PRODUCT-SERVICES INSTITUTE

John HillESYNC

TRANSYSTEMS

Susan RiderRIDER amp ASSOCIATES

Ken RuehrdanzDEMATIC

Dr John Usher UNIVERSITY OF LOUISVILLE

Col Alan B Will2D MARINE LOGISTICS GROUP

Brett WoodTOYOTA MATERIAL HANDLING USA

Peerless Media LLCA DIVISION OF EH PUBLISHING INC

Kenneth MoyesPRESIDENT AND CEOEH PUBLISHING INC

Brian CeraoloPUBLISHER AND EXECUTIVE VICE PRESIDENT

PEERLESS MEDIA LLC

MAGAZINE SUBSCRIPTIONSStart renew or update your FREE magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPhone 1-800-315-1578Mail Peerless Media PO Box 1496 Framingham MA 01701

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m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 7

reg

Member Member ofOfficial Publication of

Winner Jesse H Neal

Certificates of Merit for Journalistic

Excellence

EDITORIAL OFFICES111 Speen Street Suite 200Framingham MA 01701-1496(800) 375-8015

Michael LevansGROUP EDITORIAL DIRECTOR mlevansehpubcom

Bob TrebilcockEXECUTIVE EDITOR

roberttrebilcockmyfairpointnet

Noeumll P BodenburgEXECUTIVE MANAGING EDITOR

nbodenburgehpubcom

Lorie King RogersASSOCIATE EDITOR

lrogersehpubcom

Jeff BermanGROUP NEWS EDITOR

jbermanehpubcom

Sara Pearson SpecterEDITOR AT LARGE

saramoxiemarketingllccom

Roberto MichelEDITOR AT LARGE

robertomichelnewrrcom

Josh BondCONTRIBUTING EDITOR

turbobondgmailcom

Mike RoachCREATIVE DIRECTOR

mroachehpubcom

Wendy DelCampoART DIRECTOR

wdelcampoehpubcom

Daniel GuideraILLUSTRATION

danieldanielguideracom

Brian CeraoloGROUP PUBLISHER bceraoloehpubcom

EDITORIAL ADVISORY BOARD

Ron Giuntini OEM PRODUCT-SERVICES INSTITUTE

John HillESYNC

TRANSYSTEMS

Susan RiderRIDER amp ASSOCIATES

Ken RuehrdanzDEMATIC

Dr John Usher UNIVERSITY OF LOUISVILLE

Col Alan B Will2D MARINE LOGISTICS GROUP

Brett WoodTOYOTA MATERIAL HANDLING USA

Peerless Media LLCA DIVISION OF EH PUBLISHING INC

Kenneth MoyesPRESIDENT AND CEOEH PUBLISHING INC

Brian CeraoloPUBLISHER AND EXECUTIVE VICE PRESIDENT

PEERLESS MEDIA LLC

MAGAZINE SUBSCRIPTIONSStart renew or update your FREE magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPhone 1-800-315-1578Mail Peerless Media PO Box 1496 Framingham MA 01701

eNEWSLETTER SUBSCRIPTIONSSign up or manage your FREE eNewsletter subscriptions at wwwmmhcomenewsletters

MICHAEL LEVANSGROUP EDITORIAL

DIRECTOR

THIS MONTH IN MODERN

While it may be at a much slower pace than predicted growth is actually taking place whether

yoursquore feeling it or not In fact we kick off this monthrsquos issue with the latest report from the Material Handling Industry of America that forecasts equipment orders to grow 12 to 14 in 2010 if the current momen-tum persists (page 9)

Mind you those new numbers are com-ing off 2009 when orders saw a 343 de-cline from 2008 But any way we position the latest forecast we canrsquot help but see it as positive news for the industry overall It may even help to crack a few smiles

But while numbers donrsquot lie they can of-ten be deceiving Even though it appeared that equipment orders fell off a cliff two years ago that didnrsquot mean that materials handling professionals went into hiberna-tion in terms of executing improvement projects

In his thoughtful wrap up of HK Systemsrsquos recent Material Handling and Logistics Con-ference (page 10) executive editor Bob Tre-bilcock recounts a number of conversations that he had with attendees who were eager to share the details of the projects that they completed over the past 18 months or moved to the front burner over the past six months There was a local authority looking to put in a new ASRS the Federal Reserve Bank was investigating storage systems and even a specialty foods manufacturer looking to expand a fl eet of AGVs

ldquoI donrsquot think companies plan multi-million dollar investments in automation if

they think the apocalypse is right around the cornerrdquo observes Trebilcock

My fi rm belief that innovation never goes out of stylemdashno matter what the economic environment may bemdashhas been further validated in the system reports that have graced Modernrsquos covers over the past two years Offi ce Depot Kroger Crate amp Barrel Patagonia Bon-Ton Stores The Ap-parel Group IKEAhellipand the list goes on Each of these innovation mavericks has put precious time and strategic thought into materials handling projects that will put them in a distinct competitive advantage as the economic fog begins to clear

Itrsquos safe to say that the brutal economy never once stopped Keith Arntson vice president of distribution operations for Del Monte Foods from thinking how to he could help take miles out of the food giantrsquos distribution network by applying a few new innovations inside his To-peka Kan DC In fact after reading this monthrsquos System Report (page 18) you can say that Arntson has fl ipped over a few materials handling axioms en route to a stunning success

This month Irsquom going to leave Modern readers with a challenge After reading the Del Monte success story Irsquod like you to share with us a few of the innovation projects that yoursquove conducted during the past 18 months We believe that innovation never goes out of style now help us spread the good word and inspire a few of the late adopters Please send me an email on your better idea(s) mlevansehpubcom

Innovation never goes out of style

MMH1010_Editorialindd 7 101310 254 PM

Modern Materials Logistics Management Supply Chain Management

bull Automation

bull Conveyors amp Sorters

bull Inventory amp Picking

bull Loading Dock Equipment

bull Mobile amp Wireless

bull Shipping Pallets

bull Storage Systems

bull Containers amp Totes

bull Energy amp Sustainability

bull Lift Truck amp Fork Lift

bull Handling amp Warehouse Ergonomics

bull Packaging

bull Software amp Technology

wwwmmhcomcriticaltopics

Critical Industry News at Your Fingertips

Critical Topic areas help you develop strategies and expand your knowledge Each topic provides you with the news information and resources you need mdash each day

CRITICAL TOPICS

Modern Materials Logistics Management Supply Chain Management

MMH_CriticalTopics_Houseindd 1 81010 117 PMMMH1010_Adsindd 8 101210 1053 AM

ITrsquoS STILL A FAR CRY FROM 2007 but the materials handling industry is growing once again Following a 343 decline in equipment orders in 2009 the Material Handling Industry of America (MHIA wwwmhiaorg) is forecasting equipment orders to grow 12 to 14 in 2010 if the current momentum continues

A variety of factors are driving growth in manufacturing warehous-ing and distribution on a global basis especially an increase in industrial pro-duction in the fi rst half of 2010 despite factory utilization rates that remain very low by historical comparison

ldquoConsumer demand has not returnedrdquo Hal Vandiver executive vice president of business develop-ment for MHIA told Modern during the associationrsquos fall meeting ldquoBut in the fi rst two quarters the economy shifted from recession into recovery mode fi lling supply chain pipelines re-establishing inventories and re-sponding to pent up demandrdquo

While Vandiver expects the indus-try to continue to grow by 11 to 12 in 2011 drags on the economy continue ldquoForecasts are now calling for a combination of reduced GDP corporate profi t business investment and output growth with industrial utilization remaining below 75 until

late 2011rdquo Vandiver said ldquoThis is largely due to uncertainty Consumers inves-tors and business owners need greater confi dence in the economyrsquos ability to sustain positive growthrdquo For those reasons Vandiver doesnrsquot expect a signifi cant return to the kinds of num-bers the industry posted in the past up until 2007

In addition to

a growth in orders for new equipment Van-diver forecasts material handling shipments to grow 3 to 4 in 2010 and another 10 to 11 in 2011 Domestic demand defi ned as shipments plus imports less exports will grow by 1 in 2010 and by 10 to 11 in 2011 Exports will be stronger than im-ports in 2010 and 2011 refl ecting stronger indus-trial growth in emerging markets outside North America

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 9

Company Briefi ngs | Bob Trebilcock

The age of automationExpressed as an equation The industrial age + the information age = the automation age

mmhcomblogsautomation

Diblogbest of Modernrsquos blogs

BY BOB TREBILCOCK EXECUTIVE EDITOR

ECONOMY

MHIA Growth is backMHIA FORECASTS 12 TO 14 GROWTH IN NEW EQUIPMENT ORDERS IN 2010

0

-343

2009 2010

130(forecast)

MHIA equipment orders forecast

Source Material Handling Industry of America (MHIA)

HIGHJUMP SOFTWARE announced today that it has reached agreement to acquire TrueCommerce a provider of business-to-business integration solutions TrueCommerce provides a comprehensive end-to-end suite of trading partner connectivity solutions including electronic data interchange (EDI) translation and data mapping software transaction network and on-boarding services HighJump Software (wwwhighjumpcom) ranks

No 11 on Modernrsquos 2010 Supply Chain Management Software an-nual list with $85 million in revenue TrueCommercersquos solutions enable trading partner connectivity for 3000 customers feature predefi ned inte-gration to many major ERP systems and can be deployed in either SaaS or on-premise models

The TrueCommerce trading part-ner integration solution complements HighJump Softwarersquos existing supply

MampA

HighJump to acquire TrueCommerce

mmh1010_newsindd 9 101310 1049 AM

middot Robotic palletizing cells handle goods at the end of the production linemiddot LGVs transport pallets to stretch wrapping and labelingmiddot LGVs transport finished pallets to the warehousemiddot LGVs for Storage amp Retrieval (SRS)middot LGVs for Auto-Trailer Loading (ATL)middot An integrated software management system

Elettric 80 is a global provider of end-of-lineautomation solutions These solutions are called Freewayreg material handling system

The technologies are adaptable and have a high degree of built-in flexibility which makes them suitable for any plant warehouse layout or design More details explanatory videos and animations can be found at wwwelettric80com

ITALY middot USA middot SWEDEN middot UK middot AUSTRALIA middot POLAND

Elettric 80 Inc8100 Monticello AvenueSkokie IL 60076 USAPhone +1 847 329 7717e80usaelettric80it

Freewayreg is based on a simple idea

C

M

Y

CM

MY

CY

CMY

K

el80_US_verticalpdf 1 2010-09-29 1346

chain application suite which spans from supplier to store shelf and includes warehouse management systems transportation management systems route accounting systems manufacturing execution mobile sales and ERP data collection Trading partner collaboration is increas-ingly important as organizations strive to reduce costs and improve service levels By combining integration solutions with application functionality organizations are able to ensure consistency in business processes and accuracy of information exchanged with trading partners

ldquoTrueCommerce has fi lled a unique need in the market for simple robust and affordable EDI solutions for small and midsized businessesrdquo said Nick Manolis TrueCom-merce CEO ldquoI am excited for the TrueCommerce team to join HighJump while continuing to provide excellent service support and product innovation to our customersrdquo

ldquoCombining HighJump and TrueCommerce creates a unique and compelling solution offering within the supply chain software marketrdquo said Russell Fleischer HighJump Software CEO ldquoOur view is that supply chain applications must allow users to connect with a broad ecosystem of trading partners to maximize value The TrueCommerce solution platform and our previous move to cloud-based applications will help translate this vision into reality for our customersrdquo

SUPPLY CHAIN NEWS ANALYSIS

Final thoughts on Supply Chain Reset conferenceBY BOB TREBILCOCK EXECUTIVE EDITOR

DESPITE SIGNS OF IMPROVEMENTS doing business in in materials handling remains a challenge At the same time many of the leading customers are investing in supply chain software and automated materials handling systems to improve their businesses That suggests better times are coming

Tom Brokaw punctuates the 25th anniversary of the Material

Handling and Logistics Conference by HK Systems

mmh1010_newsindd 10 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 11

Leader of the PackThe originator of high speed narrow belt sortationTGW Systems has led the way in offering provenadvantages over conventional sortation for over 10 years

NBS fromTGW Systems

50 less install time60 less energy75 less noise

100 of the Value

wwwtgw-groupcom

TGW Systems (formerly TGW-Ermanco) is an integrated logistics solutions and material handling equipment provider The Ermanco name lives onas the product family name for the conveying andsortation products manufactured in the US

Our worldwide perspective and resources and commitment to innovation product developmentand unparalleled customer service can help you today

Proven track record ndash Over 700 installations around the world have made TGWrsquos Narrow Belt Sorter one of the most reliable sorters available

Rugged durability ndash TGWrsquos NBS sorters operate in some of the harshest distribution environments in the world earning customerrsquos admiration and competitorrsquos respect

Application and layout fl exibility ndash The universal frame on TGWrsquos narrow belt sorter means you can use multiple divert options and easily add divert modules after installation for increased fl exibility

Patented technology ndash Patented sortation technology in the TGWrsquos narrow belt sorter continues to lead the way in effective energy effi cient fl exible sortation

10 08 NBSindd 1 8302010 34008 PM

keep enough labor to run his primary distribution center Two presentations drove this point home The fi rst was from an executive with Tim Hor-tons the Dunkin Donuts of Canada The companyrsquos beautiful new DC in Guelph Ontario is underperforming projections even though the ASRS is

living up to its promises The reason The company canrsquot fi nd enough labor willing to work in its case picking and palletizing operations The other was by Terra Winston a consultant who presented a case study about a proj-ect at PepsiCo to develop the next wave of supply chain leaders Her

Those are the two high level take-aways from Supply Chain Reset the annual logistics conference held last month in Park City Utah sponsored by HK Systems now part of Dematic

ldquoLousyrdquo was the most common response to the dinner-time question ldquoHowrsquos businessrdquo

At the same time the roll call of end user companies that said they had projects in the works or on the drawing board was both a Whorsquos Who of American business with names like Coca-Cola and Kraft and companies many of us may never have heard of or think of as custom-ers of our solutions For example I sat on the van from the airport with a guy from the Los Angeles metro-politan transportation system looking for a new automated storage and retrieval system (ASRS) The Federal Reserve Bank was there investigat-ing storage systems I rode in the van back to the airport with a woman from a producer of honey in Texas who had both an ASRS and auto-matic guided vehicles in her facil-ity and was looking to expand her system

Those are signs of a growing con-fi dence I donrsquot think companies plan multi-million dollar investments in au-tomation if they think the apocalypse is right around the corner

One other anecdotal data point Marc Ducharme a vice president and partner with Axium a supplier of robotic materials handling solu-tions told me that 2009 was a dismal year for implementations but that his company has been swamped with RFPs in 2010 An RFP is not an order but itrsquos a sign

A few other observationsRetaining labor and talent could

be the most important issue facing the industry in the future A week or so before going to Utah I had a con-versation with a vice president of sup-ply chain for a major retailer who told me he is interested in automation because he simply cannot fi nd and

mmh1010_newsindd 11 101310 1049 AM

12 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

point the talent shortage isnrsquot limited just to the shop fl oor

Retrofi tting is a viable solution You know the old saying Every-thing old is new again Wegmanrsquos a Midwestern grocer and Rubber-maid both gave strong presenta-tions about how they replaced ag-ing ASRS cranes to breathe new life into their DCs Meanwhile Anheuser Busch gained new ef-fi ciencies in its Columbus Ohio facility by upgrading a warehouse control system

Everyone loves pallets Based in Iowa Green Line Armor is offering a heavy-duty hybrid woodplastic pallet for permanent pallet pools The 48- x 40-inch pallet has heavier stringers and more deck board coverage than a grocery pallet The lead boards on the top and the bottom of the palletmdashthose most likely to get damaged by a lift truckmdashare manufactured from heavy plastic The pallet has a passive RFID

tag that is used by Green Line Armor to identify the pallet and manage war-ranty services Active RFID tags were installed for John Deere the companyrsquos largest customer to track the location of work in process stored on the pallets between manufacturing processes Eric Renteria the companyrsquos president said the pallets which come with a 10-year warranty can be purchased or leased

in a pooling modelNew players are get-

ting into automation Kip Tygard whose company makes the Tygard Claw a lift truck attachment for mixed case palletizing is investing RampD money to develop an automated version of the Claw Thatrsquos not a big shock Tygard is an OEM But I also had conversations with two very large end users in the wholesale food distribu-

tion business that have designed their own automated systemsmdashone has built and implemented its own ASRS design for freezers for years the other has designed its own case picking application that it intends to put out for bid to the materials handling community Both say they may commercialize their solutions in the future

VERSATILITY MATTERSQuality Wildeck construction and versatility make the V-lifttrade the ultimate lifting solution

In todayrsquos lsquogreenrsquo building designs floor space is at a premium and moving up not out is definitely preferred Look no further than the V-Lifttrade from Wildeck ndash the industry leader in space optimization The single cylinder hydraulic system eliminates all moving hoses cables and chains Fewer components means easy installation reduced maintenance and longer service life To get more value out of your operation contact a Wildeck representative today

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MEZZANINESCapacity Matters Efficiency Matters

LIFT SYSTEMSSafety MattersGUARDING PRODUCTS

able to make better decisionsmdashespecially in the case of the unexpected ldquoWhen a shipment is held up at the portrdquo says Prashant Bhatia director of solutions management at SAP ldquoit can trigger logic back to say that Irsquove got a problem I can no longer allocate that inventory on that particular shipment as I thought I couldrdquo

3 One database one system one supply chain In the last few years soft-ware providers have been pulling all of their products onto a single supply chain process platform ldquoItrsquos fairly newrdquo says Lamphier ldquoVarious components have been integrated into that supply chain process platform longer than others but actually moving our WMS onto it has been a more recent developmentmdashjust within the last quarter or twordquo

SAP uses its enterprise resource planning (ERP) system as the central repository of information of supply and demand as well as inventory for the entire supply chain And the modules all

talk to each other Transportation man-agement systems (TMS) in conjunction with the event management modules help optimize freight determine pick-up windows determine carriers keep track of in-transit times and create ASNs

That ASN not only gets sent back to the ERP for visibility but it also gets sent to the WMS where the sys-tem uses the information to plan labor equipment and resources at the receiv-ing dock When the physical product arrives logic within the WMS based on the receipt of goods determines matches against actual demand

Smarter speedier equipment With more retailers crossdocking

over 50 of their items at the case level to their stores equipment innovations have centered on conveyor sortation systems print and apply mechanisms and automatic identifi cation technolo-gies Here are three new equipment

advances1 Smaller gaps and self-regulat-

ing conveyors In the last year the sliding shoe sorter has undergone note-worthy transformations ldquoBy doing a par-allel divert we can now run the packages closer together and get a higher through-put on the same systemrdquo reports Ken Ruehrdanz manager for Dematicrsquos distri-bution and warehousing markets

The sliding shoes that used to physi-cally push the cartons off the sorter at an angle can now run those shoes in parallel enabling smaller gaps between cartonsmdashwhich were previously from 6 inches to 8 inchesmdashdown to 3 inches

With more dense traffi c on conveyors crossdock operators can run their con-veyors at a lower speed while still achiev-ing the same throughput Slower speeds equal less wear and tear decreased energy usage and less maintenance

Another conveyor breakthrough is automatic speed control ldquoThe whole

m m h c o m MODERN MATERIALS HANDLING A P R I L 2 0 1 0 49S

MMH100401sup_Crossdock_ID 49 482010 113620 AM

Leading customers are investing in software and automated

systems to improve business according to attendees of the

Supply Chain Reset conference

mmh1010_newsindd 12 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 13

THE INDUSTRIAL REAL ESTATEmarket is taking steps in the right direction according to a report recently issued by global real estate fi rm Jones Lang LaSalle (JLL wwwjoneslanglasallecom) which report-ed the national average vacancy rate for the North American industrial real estate sector fell from 106 in the fi rst quarter to 104 in the second quarter Despite the slight decline in vacancy the fragile economy still looms large due to declining con-sumer confi dence the drying up of economic stimulus funding and the potential threat of a double-dip recession the report noted

ldquoWe have seen a positive absorp-tion in the vacancy rate in the second quarter but we are very concerned

going forwardrdquo Craig Meyer managing director and leader of JLLrsquos Logistics and Industrial Services Group told Modern ldquoAny kind of sustained demand-driven component in the industrial real estate market is going to be driven by jobs We are just not seeing any of that It is going to be a long slow recoveryrdquo

Looking at base indicators like the Institute of Supply Managementrsquos Manufacturing Index Consumer Confi dence data and industrial real estate vacancy and absorption rates there does not appear to be what Meyer labeled as a strong indication of a positive upswing on the horizon

The report says that a need to restock inventories that were running at 50-year lows resulted in large com-panies strategically capturing high

quality logistics space at cyclically low rates And with slow levels of leasing activity and sparse construc-tion industrial real estate optionsmdashespecially in the Class A large block sectormdashare limited in some markets

And the swift correction in invento-ries during the second half of 2009 and fi rst quarter of 2010 has left inventory levels lean and ready for expansion provided sales rebound in the coming months Should this occur it could lead to increased industrial and logistics real estate leasing activity

The report also pointed out that the initial recovery in the economy was largely driven by improvements in the manufacturing sector and cyclical adjustments in inventories But with the recovery now becoming more broad-based the recent slowdown of inven-tory building could have more of an impact on the industrial property sector than the offi ce sector the report noted

Date 090910 Client Rehrig Pacifi c Job 08312010 File Name 0831_RPC_SlipSheet_Ad_MMH_Oct10 Round

Account Director Niki Phan Designer Revised By ov Editor Production ov

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Publication(s) TBD Run Date(s) TBD

Approved By

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Available in standard or custom sizes with a variety of surface textures and embossed patterns Rehrig Slip Sheets provide superior slide resistance keeping goods securely in place Manufactured from nearly 100 recycled material each sheet is also 100 recyclable

Beyond the sale Rehrig can help you develop a customized re-use or buy-back program further lowering your average cost per trip

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WAREHOUSESDCS

Industrial real estate market making progress challenges remain

mmh1010_newsindd 13 101310 1049 AM

14 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

ldquoWe are also concerned about seasonality with the holiday season coming uprdquo said Meyer ldquoThe indica-tions we are getting are that we may not see as much preparation for that as we hoped A lot of retailers are saying they are restocked and if consumer confi dence is going down they are not going to build up inventories And for larger big box companies they will see declining values in rents but the availability of product for them to lease is diminishingrdquo

As a result Class A big box dis-tribution space is becoming more diffi cult to fi nd in this economy said Meyer But the build-to-suit market could come back for major retailers as evidenced by a new 1-million-square-foot DC space deal by Amazoncom in Harrisburg Pa and a 14-million-square-foot location in Phoenix

But for a mid-sized industrial building in the 100000-to-150000-square-foot range Class B-sized build-

ing Meyer said there are an infi nite number of these on the market

Looking ahead Meyer said there will still be downward pressure on pric-

ing a double-digit vacancy rate and no increases in lease rates which he noted are actually weakening a little bit and tend to lag a recovery

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CROWN EQUIPMENT Corp has quali-fi ed 20 of its electric models to operate with various fuel cells bringing the total of qualifi ed combinations of fuel cell packs and trucks to 29 In 2009 Crown (wwwcrowncom) was the fi rst lift truck manufacturer to introduce a fuel cell qualifi cation program

Eric Jensen Crownrsquos manager of new technology research and de-velopment told Modern that the companyrsquos fuel cell qualifi cation pro-gram duplicates its own testing and is conducted at a 25000-square-foot research facility near Dayton Ohio Through the testing process engi-

neers evaluate fuel cell performance and monitor whether issues develop that affect the truckrsquos operation

To qualify a fuel cell pack and truck combination Crownrsquos engineers review key performance metrics for a battery-powered truck such as traction plug-ging and lift and travel speeds Then they replace the battery with a fuel cell power pack and measure the same indicators Through modeling and ap-plication testing the research team de-termines design modifi cations needed to ensure the fuel cell-powered forklift matched standards to which the truck was designed

LIFT TRUCKS

Crown unveils 20 electric lift trucks to operate with fuel cells

mmh1010_newsindd 14 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 15

ldquoWersquove been steadfast in our posi-tion that deployment of a fuel cell forklift fl eet must be carefully evalu-ated and tested for appropriate use in a warehouserdquo said Jensen ldquoThis research-based approach means that our customers can confi dently know they have the right truck for their chosen fuel cell allowing them to meet their performance safety and

environmental sus-tainability goalsrdquo

Crown continues to work closely with fuel cell manufactur-ers and customers to qualify trucks as new fuel cell pack models are intro-duced ldquoForklifts are a key early market for fuel cellsrdquo said Lisa Callaghan Jerram senior market analyst for Fuel Cell Today a leading analyst

fi rm providing market-based research on the fuel cell industry ldquoBased on our market research we have found strong growth in this sector in the past three yearsrdquo

Because fuel cell powered electric forklifts give off exhaust in the form of moist warm air IC truck custom-ers are looking to this technology

so they donrsquot have to deal exhaust issues Jensen said Another advan-tage pointed out by Jensen is a fuel cell powered truckrsquos ability to effec-tively operate in a cold environment because they generate their own heat and the power doesnrsquot fall off like a traditional battery

While the upfront hardware cost of fuel cells is more expensive than a traditional battery Jensen pointed out the potential to capture savings in labor battery changes battery rooms and heating and venting With fuel cells he said a facility doesnrsquot need a battery room and all that goes in to running it properly Instead there is an ongoing savings associated to using fl oor space for production or other value-added operations

ldquoFuel cells have always been talked about fi ve years into the future but we have customers who are [currently] planning installations around this prod-uctrdquo said Jensen ldquoThe future is hererdquo

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To qualify a fuel cell pack and truck combination engineers

review key performance metrics

mmh1010_newsindd 15 101310 1049 AM

lift truck TIPS

GraphicCaption

In the right application tuggers and carts can be a fast and efficient solution

Level the playing field

Football season is under-way and fans are hoping for breakout performances

from stars and rookies alike On the gridiron an overpowered player can be a distinct advan-tage In the warehouse how-ever too much power can lead to waste danger and sluggish performance For some corpo-rations this fact has prompted consideration of fork-free envi-ronments where versatile and custom-built carts and tuggers can do the work faster and more efficiently than their big-ger cousins

Disposing of expensive and powerful equipment in favor of carts may seem counter-intuitive but Jill Burrow marketing manager for Topper Industrial says certain warehouses might benefit greatly from the switch For operations requiring multiple trips between the same areas carts can cut travel time sig-nificantly According to Ed Brown president of Topper Industrial a tugger can pull as many as 13 carts In addi-tion says Brown carts and tuggers can be easier to use than many forklifts

ldquoA forklift costs five times as much but a forklift opera-tor also costs five times more than a tugger operatorrdquo says Brown ldquoAnyone can grab a tugger and gordquo

Once a forklift drops off a pallet in many cases a picker must bend to access product or arrange for the pallet to be lifted Carts on the other hand can be configured with swiveling or angled platforms to allow pickers fast and comfortable access to products Worker safety issues tied to forklifts that operate in tight areas such as poor visibility when driving in re-verse and dock mishaps can also be greatly reduced

ldquoCompanies looking at carts are looking at the cost of equipment and the cost of maintenance but theyrsquore also looking at safetyrdquo says Brown

In addition to ergonomics and safety a fork-free zone might help a warehouse reduce product loss and equip-ment damage Carts provide a secure cradle for moving product while some fork-borne loads are prone to top-pling And forklifts often 10 times as heavy as a tugger and cart setup have a way of proving their strength by leaving dings and dents on storage racks and other hap-less stationary objects

With carts and tuggers Brown says most companies see a return on investment within a year In football a first-round draft pick can cost millions over a multi-year contract before he produces the desired results For com-panies not looking to attempt such a Hail Mary tuggers could prove an efficient alternative

Josh Bond is a contributing editor to Modern and can be reached at turbobondgmailcom

16 O c t O b e r 2 0 1 0 Modern Materials Handling m m h c o m

lift truck TIPS

By Josh Bond Contributing Editor

MMH1010_LiftTruckTipsindd 16 101310 942 AM

MM100601Adsindd 3 6310 349 PMMMH1010_Adsindd 17 101210 1053 AM

18 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

Keith arntson vice president of distribution operations for

del Monte Foods

Four conveyor-topped vehicles ferry loads from an adjacent manufacturing plant

MMH1010_SystemRptDelMonteindd 18 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

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Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

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ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

bull Discover the newest robotics products and services bull See the latest robot-based solutions for picking and palletizing bull Understand how intelligent robots are revolutionizing processing

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ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

Denso RoboticsElite EngineeringFANUC RoboticsFood EngineeringGenesis Systems GroupHartness InternationalKIva Systems

Modern Materials HandlingMotion Control RoboticsNational InstrumentsOmron Scientifi c Technologies IncRobotics TrendsWind RiverYaskawa Motoman Robotics

MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

chepcomsimplechoice

Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

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Find us on

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MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

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Holster YourSide Arm

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LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

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MY

CY

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classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

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career Opportunities

To advertise or for more

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Jennifer Drevline

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bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 6: Modern Materials Handling - October 2010

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 5

PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION WAREHOUSING AND MANUFACTURING

VOL 65 NO 10

DEPARTMENTS amp COLUMNS 3 Upfront 7 This Month in Modern16 Lift Truck Tips Level the playing field38 Focus On Palletizers42 Supplement WarehousesDCs50 60 seconds with

NEWS 9 MHIA Growth is back 9 HighJump to acquire TrueCommerce10 Final thoughts on Supply Chain Reset13 Industrial real estate market making

progress challenges remain

14 Crown unveils 20 electric lift trucks to operate with fuel cells

COVER STORYSYSTEM REPORT

18 Best in classDel Monte Foodsrsquo new Topeka DC brings laser-guided AGVs from manufacturing into distribution The result is a best-in-class materials handling system that minimizes costs with room to expand in the future

22 Automatic guided vehicles streamline operationsLaser-guided AGVs move product from the manufacturing plant and through the distribution center

FEATURESPRODUCTIVITY SOLUTION

25 Tilt toward safety and productivityAluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

SPECIAL REPORT

26 Top 20 automatic data capture suppliersThe ADC market took a significant hit in 2009 but the recovery may already be underway

INFORMATION MANAGEMENT

30 In sync Data capture and mobile computing Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

EQUIPMENT REPORT

34 Carousels Turning picking into productivityNot just for high-density storage anymore todayrsquos carousels are delivering product to the person while increasing productivity reducing labor saving space and cutting energy costs

60 seconds with Joan Barrett Kellogg p 50

Modern Materials Handling reg (ISSN 0026-8038) is published monthly by Peerless Media LLC a Division of EH Publishing Inc 111 Speen St Suite 200 Framingham MA 01701 Annual subscription rates for non-qualifi ed subscribers USA $119 Canada $159 Other International $249 Single copies are available for $2000 Send all subscription inquiries to Modern Materials Handling 111 Speen Street Suite 200 Framingham MA 01701 USA Periodicals postage paid at Framingham MA and additional mailing offi ces POSTMASTER Send address changes to Modern Materials Handling PO Box 1496 Framingham MA 01701-1496 Reproduction of this magazine in whole or part without written permis-sion of the publisher is prohibited All rights reserved (C)2010 Peerless Media LLC

reg

PHOTO BLAINE FISHERGETTY IMAGES

Keith Arntson and his team at Del Monte put a fl eet of laser-guided AGVs to work at their DC

handling system that minimizes costs with room to expand in the future

60 seconds with Joan Barrett Kellogg p 50

BLAINE FISHERGETTY IMAGES

MMH1010_TOCindd 5 101310 947 AM

Introducing the new Automatic Destratification System

Big Ass Fans have always saved money in the winter but now it can be done with the push of a button The patent pending Automatic Destratification System keeps your space at the perfect temperature year-round from floor to ceiling The Automatic Destratification System calculates the floor-to-ceiling temperature differential and modulates the fanrsquos speed so you donrsquot have to

Bottom line you could save up to 30 on your heating bills this winterhellip and next winterhellip and next winterhellip

pending Automatic Destratification System keeps your space

Bottom line you could save up to 30 on your heating bills

NEWNEWNEW

Visit wwwBigAssFanscom or call 877-BIG FANS (877-244-3267) to learn moreAn ISO 90012008 certified company

If global warming doesnrsquot reduce your energy costs this winter perhaps we can help

Covered by one or more of the following US Patents 6244821 6589016 6817835 6939108 7252478 7284960 7654798 D587799 D607988 and other patents pending

10 year parts 1 year labor warranty certain exclusions apply See complete warranty for details copy 2010 Delta T Corporation dba The Big Ass Fan Company All rights reserved

BAF_MMH_DestratAd_091610indd 1 91710 851 AMMMH1010_Adsindd 6 101210 1053 AM

EDITORIAL OFFICES111 Speen Street Suite 200Framingham MA 01701-1496(800) 375-8015

Michael LevansGROUP EDITORIAL DIRECTOR mlevansehpubcom

Bob TrebilcockEXECUTIVE EDITOR

roberttrebilcockmyfairpointnet

Noeumll P BodenburgEXECUTIVE MANAGING EDITOR

nbodenburgehpubcom

Lorie King RogersASSOCIATE EDITOR

lrogersehpubcom

Sara Pearson SpecterEDITOR AT LARGE

saramoxiemarketingllccom

Roberto MichelEDITOR AT LARGE

robertomichelnewrrcom

Tom AndelCOLUMNIST

tandel4315aolcom

Jeff BermanGROUP NEWS EDITOR

jbermanehpubcom

Josh BondCONTRIBUTING EDITOR

turbobondgmailcom

Mike RoachCREATIVE DIRECTOR

mroachehpubcom

Wendy DelCampoART DIRECTOR

wdelcampoehpubcom

Daniel GuideraILLUSTRATION

danieldanielguideracom

Brian CeraoloGROUP PUBLISHER bceraoloehpubcom

EDITORIAL ADVISORY BOARD

Ron Giuntini OEM PRODUCT-SERVICES INSTITUTE

John HillESYNC

TRANSYSTEMS

Susan RiderRIDER amp ASSOCIATES

Ken RuehrdanzDEMATIC

Dr John Usher UNIVERSITY OF LOUISVILLE

Col Alan B Will2D MARINE LOGISTICS GROUP

Brett WoodTOYOTA MATERIAL HANDLING USA

Peerless Media LLCA DIVISION OF EH PUBLISHING INC

Kenneth MoyesPRESIDENT AND CEOEH PUBLISHING INC

Brian CeraoloPUBLISHER AND EXECUTIVE VICE PRESIDENT

PEERLESS MEDIA LLC

MAGAZINE SUBSCRIPTIONSStart renew or update your FREE magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPhone 1-800-315-1578Mail Peerless Media PO Box 1496 Framingham MA 01701

eNEWSLETTER SUBSCRIPTIONSSign up or manage your FREE eNewsletter subscriptions at wwwmmhcomenewsletters

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 7

reg

Member Member ofOfficial Publication of

Winner Jesse H Neal

Certificates of Merit for Journalistic

Excellence

EDITORIAL OFFICES111 Speen Street Suite 200Framingham MA 01701-1496(800) 375-8015

Michael LevansGROUP EDITORIAL DIRECTOR mlevansehpubcom

Bob TrebilcockEXECUTIVE EDITOR

roberttrebilcockmyfairpointnet

Noeumll P BodenburgEXECUTIVE MANAGING EDITOR

nbodenburgehpubcom

Lorie King RogersASSOCIATE EDITOR

lrogersehpubcom

Jeff BermanGROUP NEWS EDITOR

jbermanehpubcom

Sara Pearson SpecterEDITOR AT LARGE

saramoxiemarketingllccom

Roberto MichelEDITOR AT LARGE

robertomichelnewrrcom

Josh BondCONTRIBUTING EDITOR

turbobondgmailcom

Mike RoachCREATIVE DIRECTOR

mroachehpubcom

Wendy DelCampoART DIRECTOR

wdelcampoehpubcom

Daniel GuideraILLUSTRATION

danieldanielguideracom

Brian CeraoloGROUP PUBLISHER bceraoloehpubcom

EDITORIAL ADVISORY BOARD

Ron Giuntini OEM PRODUCT-SERVICES INSTITUTE

John HillESYNC

TRANSYSTEMS

Susan RiderRIDER amp ASSOCIATES

Ken RuehrdanzDEMATIC

Dr John Usher UNIVERSITY OF LOUISVILLE

Col Alan B Will2D MARINE LOGISTICS GROUP

Brett WoodTOYOTA MATERIAL HANDLING USA

Peerless Media LLCA DIVISION OF EH PUBLISHING INC

Kenneth MoyesPRESIDENT AND CEOEH PUBLISHING INC

Brian CeraoloPUBLISHER AND EXECUTIVE VICE PRESIDENT

PEERLESS MEDIA LLC

MAGAZINE SUBSCRIPTIONSStart renew or update your FREE magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPhone 1-800-315-1578Mail Peerless Media PO Box 1496 Framingham MA 01701

eNEWSLETTER SUBSCRIPTIONSSign up or manage your FREE eNewsletter subscriptions at wwwmmhcomenewsletters

MICHAEL LEVANSGROUP EDITORIAL

DIRECTOR

THIS MONTH IN MODERN

While it may be at a much slower pace than predicted growth is actually taking place whether

yoursquore feeling it or not In fact we kick off this monthrsquos issue with the latest report from the Material Handling Industry of America that forecasts equipment orders to grow 12 to 14 in 2010 if the current momen-tum persists (page 9)

Mind you those new numbers are com-ing off 2009 when orders saw a 343 de-cline from 2008 But any way we position the latest forecast we canrsquot help but see it as positive news for the industry overall It may even help to crack a few smiles

But while numbers donrsquot lie they can of-ten be deceiving Even though it appeared that equipment orders fell off a cliff two years ago that didnrsquot mean that materials handling professionals went into hiberna-tion in terms of executing improvement projects

In his thoughtful wrap up of HK Systemsrsquos recent Material Handling and Logistics Con-ference (page 10) executive editor Bob Tre-bilcock recounts a number of conversations that he had with attendees who were eager to share the details of the projects that they completed over the past 18 months or moved to the front burner over the past six months There was a local authority looking to put in a new ASRS the Federal Reserve Bank was investigating storage systems and even a specialty foods manufacturer looking to expand a fl eet of AGVs

ldquoI donrsquot think companies plan multi-million dollar investments in automation if

they think the apocalypse is right around the cornerrdquo observes Trebilcock

My fi rm belief that innovation never goes out of stylemdashno matter what the economic environment may bemdashhas been further validated in the system reports that have graced Modernrsquos covers over the past two years Offi ce Depot Kroger Crate amp Barrel Patagonia Bon-Ton Stores The Ap-parel Group IKEAhellipand the list goes on Each of these innovation mavericks has put precious time and strategic thought into materials handling projects that will put them in a distinct competitive advantage as the economic fog begins to clear

Itrsquos safe to say that the brutal economy never once stopped Keith Arntson vice president of distribution operations for Del Monte Foods from thinking how to he could help take miles out of the food giantrsquos distribution network by applying a few new innovations inside his To-peka Kan DC In fact after reading this monthrsquos System Report (page 18) you can say that Arntson has fl ipped over a few materials handling axioms en route to a stunning success

This month Irsquom going to leave Modern readers with a challenge After reading the Del Monte success story Irsquod like you to share with us a few of the innovation projects that yoursquove conducted during the past 18 months We believe that innovation never goes out of style now help us spread the good word and inspire a few of the late adopters Please send me an email on your better idea(s) mlevansehpubcom

Innovation never goes out of style

MMH1010_Editorialindd 7 101310 254 PM

Modern Materials Logistics Management Supply Chain Management

bull Automation

bull Conveyors amp Sorters

bull Inventory amp Picking

bull Loading Dock Equipment

bull Mobile amp Wireless

bull Shipping Pallets

bull Storage Systems

bull Containers amp Totes

bull Energy amp Sustainability

bull Lift Truck amp Fork Lift

bull Handling amp Warehouse Ergonomics

bull Packaging

bull Software amp Technology

wwwmmhcomcriticaltopics

Critical Industry News at Your Fingertips

Critical Topic areas help you develop strategies and expand your knowledge Each topic provides you with the news information and resources you need mdash each day

CRITICAL TOPICS

Modern Materials Logistics Management Supply Chain Management

MMH_CriticalTopics_Houseindd 1 81010 117 PMMMH1010_Adsindd 8 101210 1053 AM

ITrsquoS STILL A FAR CRY FROM 2007 but the materials handling industry is growing once again Following a 343 decline in equipment orders in 2009 the Material Handling Industry of America (MHIA wwwmhiaorg) is forecasting equipment orders to grow 12 to 14 in 2010 if the current momentum continues

A variety of factors are driving growth in manufacturing warehous-ing and distribution on a global basis especially an increase in industrial pro-duction in the fi rst half of 2010 despite factory utilization rates that remain very low by historical comparison

ldquoConsumer demand has not returnedrdquo Hal Vandiver executive vice president of business develop-ment for MHIA told Modern during the associationrsquos fall meeting ldquoBut in the fi rst two quarters the economy shifted from recession into recovery mode fi lling supply chain pipelines re-establishing inventories and re-sponding to pent up demandrdquo

While Vandiver expects the indus-try to continue to grow by 11 to 12 in 2011 drags on the economy continue ldquoForecasts are now calling for a combination of reduced GDP corporate profi t business investment and output growth with industrial utilization remaining below 75 until

late 2011rdquo Vandiver said ldquoThis is largely due to uncertainty Consumers inves-tors and business owners need greater confi dence in the economyrsquos ability to sustain positive growthrdquo For those reasons Vandiver doesnrsquot expect a signifi cant return to the kinds of num-bers the industry posted in the past up until 2007

In addition to

a growth in orders for new equipment Van-diver forecasts material handling shipments to grow 3 to 4 in 2010 and another 10 to 11 in 2011 Domestic demand defi ned as shipments plus imports less exports will grow by 1 in 2010 and by 10 to 11 in 2011 Exports will be stronger than im-ports in 2010 and 2011 refl ecting stronger indus-trial growth in emerging markets outside North America

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 9

Company Briefi ngs | Bob Trebilcock

The age of automationExpressed as an equation The industrial age + the information age = the automation age

mmhcomblogsautomation

Diblogbest of Modernrsquos blogs

BY BOB TREBILCOCK EXECUTIVE EDITOR

ECONOMY

MHIA Growth is backMHIA FORECASTS 12 TO 14 GROWTH IN NEW EQUIPMENT ORDERS IN 2010

0

-343

2009 2010

130(forecast)

MHIA equipment orders forecast

Source Material Handling Industry of America (MHIA)

HIGHJUMP SOFTWARE announced today that it has reached agreement to acquire TrueCommerce a provider of business-to-business integration solutions TrueCommerce provides a comprehensive end-to-end suite of trading partner connectivity solutions including electronic data interchange (EDI) translation and data mapping software transaction network and on-boarding services HighJump Software (wwwhighjumpcom) ranks

No 11 on Modernrsquos 2010 Supply Chain Management Software an-nual list with $85 million in revenue TrueCommercersquos solutions enable trading partner connectivity for 3000 customers feature predefi ned inte-gration to many major ERP systems and can be deployed in either SaaS or on-premise models

The TrueCommerce trading part-ner integration solution complements HighJump Softwarersquos existing supply

MampA

HighJump to acquire TrueCommerce

mmh1010_newsindd 9 101310 1049 AM

middot Robotic palletizing cells handle goods at the end of the production linemiddot LGVs transport pallets to stretch wrapping and labelingmiddot LGVs transport finished pallets to the warehousemiddot LGVs for Storage amp Retrieval (SRS)middot LGVs for Auto-Trailer Loading (ATL)middot An integrated software management system

Elettric 80 is a global provider of end-of-lineautomation solutions These solutions are called Freewayreg material handling system

The technologies are adaptable and have a high degree of built-in flexibility which makes them suitable for any plant warehouse layout or design More details explanatory videos and animations can be found at wwwelettric80com

ITALY middot USA middot SWEDEN middot UK middot AUSTRALIA middot POLAND

Elettric 80 Inc8100 Monticello AvenueSkokie IL 60076 USAPhone +1 847 329 7717e80usaelettric80it

Freewayreg is based on a simple idea

C

M

Y

CM

MY

CY

CMY

K

el80_US_verticalpdf 1 2010-09-29 1346

chain application suite which spans from supplier to store shelf and includes warehouse management systems transportation management systems route accounting systems manufacturing execution mobile sales and ERP data collection Trading partner collaboration is increas-ingly important as organizations strive to reduce costs and improve service levels By combining integration solutions with application functionality organizations are able to ensure consistency in business processes and accuracy of information exchanged with trading partners

ldquoTrueCommerce has fi lled a unique need in the market for simple robust and affordable EDI solutions for small and midsized businessesrdquo said Nick Manolis TrueCom-merce CEO ldquoI am excited for the TrueCommerce team to join HighJump while continuing to provide excellent service support and product innovation to our customersrdquo

ldquoCombining HighJump and TrueCommerce creates a unique and compelling solution offering within the supply chain software marketrdquo said Russell Fleischer HighJump Software CEO ldquoOur view is that supply chain applications must allow users to connect with a broad ecosystem of trading partners to maximize value The TrueCommerce solution platform and our previous move to cloud-based applications will help translate this vision into reality for our customersrdquo

SUPPLY CHAIN NEWS ANALYSIS

Final thoughts on Supply Chain Reset conferenceBY BOB TREBILCOCK EXECUTIVE EDITOR

DESPITE SIGNS OF IMPROVEMENTS doing business in in materials handling remains a challenge At the same time many of the leading customers are investing in supply chain software and automated materials handling systems to improve their businesses That suggests better times are coming

Tom Brokaw punctuates the 25th anniversary of the Material

Handling and Logistics Conference by HK Systems

mmh1010_newsindd 10 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 11

Leader of the PackThe originator of high speed narrow belt sortationTGW Systems has led the way in offering provenadvantages over conventional sortation for over 10 years

NBS fromTGW Systems

50 less install time60 less energy75 less noise

100 of the Value

wwwtgw-groupcom

TGW Systems (formerly TGW-Ermanco) is an integrated logistics solutions and material handling equipment provider The Ermanco name lives onas the product family name for the conveying andsortation products manufactured in the US

Our worldwide perspective and resources and commitment to innovation product developmentand unparalleled customer service can help you today

Proven track record ndash Over 700 installations around the world have made TGWrsquos Narrow Belt Sorter one of the most reliable sorters available

Rugged durability ndash TGWrsquos NBS sorters operate in some of the harshest distribution environments in the world earning customerrsquos admiration and competitorrsquos respect

Application and layout fl exibility ndash The universal frame on TGWrsquos narrow belt sorter means you can use multiple divert options and easily add divert modules after installation for increased fl exibility

Patented technology ndash Patented sortation technology in the TGWrsquos narrow belt sorter continues to lead the way in effective energy effi cient fl exible sortation

10 08 NBSindd 1 8302010 34008 PM

keep enough labor to run his primary distribution center Two presentations drove this point home The fi rst was from an executive with Tim Hor-tons the Dunkin Donuts of Canada The companyrsquos beautiful new DC in Guelph Ontario is underperforming projections even though the ASRS is

living up to its promises The reason The company canrsquot fi nd enough labor willing to work in its case picking and palletizing operations The other was by Terra Winston a consultant who presented a case study about a proj-ect at PepsiCo to develop the next wave of supply chain leaders Her

Those are the two high level take-aways from Supply Chain Reset the annual logistics conference held last month in Park City Utah sponsored by HK Systems now part of Dematic

ldquoLousyrdquo was the most common response to the dinner-time question ldquoHowrsquos businessrdquo

At the same time the roll call of end user companies that said they had projects in the works or on the drawing board was both a Whorsquos Who of American business with names like Coca-Cola and Kraft and companies many of us may never have heard of or think of as custom-ers of our solutions For example I sat on the van from the airport with a guy from the Los Angeles metro-politan transportation system looking for a new automated storage and retrieval system (ASRS) The Federal Reserve Bank was there investigat-ing storage systems I rode in the van back to the airport with a woman from a producer of honey in Texas who had both an ASRS and auto-matic guided vehicles in her facil-ity and was looking to expand her system

Those are signs of a growing con-fi dence I donrsquot think companies plan multi-million dollar investments in au-tomation if they think the apocalypse is right around the corner

One other anecdotal data point Marc Ducharme a vice president and partner with Axium a supplier of robotic materials handling solu-tions told me that 2009 was a dismal year for implementations but that his company has been swamped with RFPs in 2010 An RFP is not an order but itrsquos a sign

A few other observationsRetaining labor and talent could

be the most important issue facing the industry in the future A week or so before going to Utah I had a con-versation with a vice president of sup-ply chain for a major retailer who told me he is interested in automation because he simply cannot fi nd and

mmh1010_newsindd 11 101310 1049 AM

12 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

point the talent shortage isnrsquot limited just to the shop fl oor

Retrofi tting is a viable solution You know the old saying Every-thing old is new again Wegmanrsquos a Midwestern grocer and Rubber-maid both gave strong presenta-tions about how they replaced ag-ing ASRS cranes to breathe new life into their DCs Meanwhile Anheuser Busch gained new ef-fi ciencies in its Columbus Ohio facility by upgrading a warehouse control system

Everyone loves pallets Based in Iowa Green Line Armor is offering a heavy-duty hybrid woodplastic pallet for permanent pallet pools The 48- x 40-inch pallet has heavier stringers and more deck board coverage than a grocery pallet The lead boards on the top and the bottom of the palletmdashthose most likely to get damaged by a lift truckmdashare manufactured from heavy plastic The pallet has a passive RFID

tag that is used by Green Line Armor to identify the pallet and manage war-ranty services Active RFID tags were installed for John Deere the companyrsquos largest customer to track the location of work in process stored on the pallets between manufacturing processes Eric Renteria the companyrsquos president said the pallets which come with a 10-year warranty can be purchased or leased

in a pooling modelNew players are get-

ting into automation Kip Tygard whose company makes the Tygard Claw a lift truck attachment for mixed case palletizing is investing RampD money to develop an automated version of the Claw Thatrsquos not a big shock Tygard is an OEM But I also had conversations with two very large end users in the wholesale food distribu-

tion business that have designed their own automated systemsmdashone has built and implemented its own ASRS design for freezers for years the other has designed its own case picking application that it intends to put out for bid to the materials handling community Both say they may commercialize their solutions in the future

VERSATILITY MATTERSQuality Wildeck construction and versatility make the V-lifttrade the ultimate lifting solution

In todayrsquos lsquogreenrsquo building designs floor space is at a premium and moving up not out is definitely preferred Look no further than the V-Lifttrade from Wildeck ndash the industry leader in space optimization The single cylinder hydraulic system eliminates all moving hoses cables and chains Fewer components means easy installation reduced maintenance and longer service life To get more value out of your operation contact a Wildeck representative today

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800-325-6939 | WWWWILDECKCOM

MEZZANINESCapacity Matters Efficiency Matters

LIFT SYSTEMSSafety MattersGUARDING PRODUCTS

able to make better decisionsmdashespecially in the case of the unexpected ldquoWhen a shipment is held up at the portrdquo says Prashant Bhatia director of solutions management at SAP ldquoit can trigger logic back to say that Irsquove got a problem I can no longer allocate that inventory on that particular shipment as I thought I couldrdquo

3 One database one system one supply chain In the last few years soft-ware providers have been pulling all of their products onto a single supply chain process platform ldquoItrsquos fairly newrdquo says Lamphier ldquoVarious components have been integrated into that supply chain process platform longer than others but actually moving our WMS onto it has been a more recent developmentmdashjust within the last quarter or twordquo

SAP uses its enterprise resource planning (ERP) system as the central repository of information of supply and demand as well as inventory for the entire supply chain And the modules all

talk to each other Transportation man-agement systems (TMS) in conjunction with the event management modules help optimize freight determine pick-up windows determine carriers keep track of in-transit times and create ASNs

That ASN not only gets sent back to the ERP for visibility but it also gets sent to the WMS where the sys-tem uses the information to plan labor equipment and resources at the receiv-ing dock When the physical product arrives logic within the WMS based on the receipt of goods determines matches against actual demand

Smarter speedier equipment With more retailers crossdocking

over 50 of their items at the case level to their stores equipment innovations have centered on conveyor sortation systems print and apply mechanisms and automatic identifi cation technolo-gies Here are three new equipment

advances1 Smaller gaps and self-regulat-

ing conveyors In the last year the sliding shoe sorter has undergone note-worthy transformations ldquoBy doing a par-allel divert we can now run the packages closer together and get a higher through-put on the same systemrdquo reports Ken Ruehrdanz manager for Dematicrsquos distri-bution and warehousing markets

The sliding shoes that used to physi-cally push the cartons off the sorter at an angle can now run those shoes in parallel enabling smaller gaps between cartonsmdashwhich were previously from 6 inches to 8 inchesmdashdown to 3 inches

With more dense traffi c on conveyors crossdock operators can run their con-veyors at a lower speed while still achiev-ing the same throughput Slower speeds equal less wear and tear decreased energy usage and less maintenance

Another conveyor breakthrough is automatic speed control ldquoThe whole

m m h c o m MODERN MATERIALS HANDLING A P R I L 2 0 1 0 49S

MMH100401sup_Crossdock_ID 49 482010 113620 AM

Leading customers are investing in software and automated

systems to improve business according to attendees of the

Supply Chain Reset conference

mmh1010_newsindd 12 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 13

THE INDUSTRIAL REAL ESTATEmarket is taking steps in the right direction according to a report recently issued by global real estate fi rm Jones Lang LaSalle (JLL wwwjoneslanglasallecom) which report-ed the national average vacancy rate for the North American industrial real estate sector fell from 106 in the fi rst quarter to 104 in the second quarter Despite the slight decline in vacancy the fragile economy still looms large due to declining con-sumer confi dence the drying up of economic stimulus funding and the potential threat of a double-dip recession the report noted

ldquoWe have seen a positive absorp-tion in the vacancy rate in the second quarter but we are very concerned

going forwardrdquo Craig Meyer managing director and leader of JLLrsquos Logistics and Industrial Services Group told Modern ldquoAny kind of sustained demand-driven component in the industrial real estate market is going to be driven by jobs We are just not seeing any of that It is going to be a long slow recoveryrdquo

Looking at base indicators like the Institute of Supply Managementrsquos Manufacturing Index Consumer Confi dence data and industrial real estate vacancy and absorption rates there does not appear to be what Meyer labeled as a strong indication of a positive upswing on the horizon

The report says that a need to restock inventories that were running at 50-year lows resulted in large com-panies strategically capturing high

quality logistics space at cyclically low rates And with slow levels of leasing activity and sparse construc-tion industrial real estate optionsmdashespecially in the Class A large block sectormdashare limited in some markets

And the swift correction in invento-ries during the second half of 2009 and fi rst quarter of 2010 has left inventory levels lean and ready for expansion provided sales rebound in the coming months Should this occur it could lead to increased industrial and logistics real estate leasing activity

The report also pointed out that the initial recovery in the economy was largely driven by improvements in the manufacturing sector and cyclical adjustments in inventories But with the recovery now becoming more broad-based the recent slowdown of inven-tory building could have more of an impact on the industrial property sector than the offi ce sector the report noted

Date 090910 Client Rehrig Pacifi c Job 08312010 File Name 0831_RPC_SlipSheet_Ad_MMH_Oct10 Round

Account Director Niki Phan Designer Revised By ov Editor Production ov

Color 4CProcess Trim 7 times 4625 Bleed 0 Safety 675times 4375 Fold na

Publication(s) TBD Run Date(s) TBD

Approved By

A FAMILY TRADITION OF GROWTH SERVICE AND INNOVATION

Give Your Heavy Pallets the Slip

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Ship more product per load with Rehrigrsquos weight space and cost saving Slip Sheets

Rehrig co-extruded Slip Sheets are a cost-effective alternative to pallets Impervious to moisture high tensile strength plastic provides added tear resistance making them the perfect replacement for fi ber or corrugated sheets as well

Available in standard or custom sizes with a variety of surface textures and embossed patterns Rehrig Slip Sheets provide superior slide resistance keeping goods securely in place Manufactured from nearly 100 recycled material each sheet is also 100 recyclable

Beyond the sale Rehrig can help you develop a customized re-use or buy-back program further lowering your average cost per trip

Phone (800) 546-4993 Email inforehrigpacificcom Web wwwrehrigpacificcom

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Come see us at Pack ExpoBooth S-5000

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WAREHOUSESDCS

Industrial real estate market making progress challenges remain

mmh1010_newsindd 13 101310 1049 AM

14 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

ldquoWe are also concerned about seasonality with the holiday season coming uprdquo said Meyer ldquoThe indica-tions we are getting are that we may not see as much preparation for that as we hoped A lot of retailers are saying they are restocked and if consumer confi dence is going down they are not going to build up inventories And for larger big box companies they will see declining values in rents but the availability of product for them to lease is diminishingrdquo

As a result Class A big box dis-tribution space is becoming more diffi cult to fi nd in this economy said Meyer But the build-to-suit market could come back for major retailers as evidenced by a new 1-million-square-foot DC space deal by Amazoncom in Harrisburg Pa and a 14-million-square-foot location in Phoenix

But for a mid-sized industrial building in the 100000-to-150000-square-foot range Class B-sized build-

ing Meyer said there are an infi nite number of these on the market

Looking ahead Meyer said there will still be downward pressure on pric-

ing a double-digit vacancy rate and no increases in lease rates which he noted are actually weakening a little bit and tend to lag a recovery

Power AND CoNtrol

Introducing the latest innovations for incorporating Power AND Control into

your 24 VDC conveyor system

For over 60 years Itoh Denki has been the proven leader in the development and manufacture of superior motorized rollers and components This history provides you confidence in your 24V conveyor applications and designs a confidence based on the component integrity offered by the only sole source motor and control manufacturer in the industry

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Intelligent solutions yoursquod expect from Itoh Denki Intelligent solutions yoursquod expect from Itoh Denki

BFL SERIESldquoBIG FRIGGIN

LIFTrdquoBFL lifts are designed to move large loads ormultiple pallets betweenfloors These lifts willtravel from 8 feet to 18feet and have platformsizes ranging from 6rsquo x 8rsquo up to 8rsquo x 12rsquoThey are ideal for movinglarge loads 1-2 floors orup to high stages andmezzanines

1-800-843-3625wwwadvancel i f ts com

BFL AD MMH APRIL 92710 358 PM Page 1

CROWN EQUIPMENT Corp has quali-fi ed 20 of its electric models to operate with various fuel cells bringing the total of qualifi ed combinations of fuel cell packs and trucks to 29 In 2009 Crown (wwwcrowncom) was the fi rst lift truck manufacturer to introduce a fuel cell qualifi cation program

Eric Jensen Crownrsquos manager of new technology research and de-velopment told Modern that the companyrsquos fuel cell qualifi cation pro-gram duplicates its own testing and is conducted at a 25000-square-foot research facility near Dayton Ohio Through the testing process engi-

neers evaluate fuel cell performance and monitor whether issues develop that affect the truckrsquos operation

To qualify a fuel cell pack and truck combination Crownrsquos engineers review key performance metrics for a battery-powered truck such as traction plug-ging and lift and travel speeds Then they replace the battery with a fuel cell power pack and measure the same indicators Through modeling and ap-plication testing the research team de-termines design modifi cations needed to ensure the fuel cell-powered forklift matched standards to which the truck was designed

LIFT TRUCKS

Crown unveils 20 electric lift trucks to operate with fuel cells

mmh1010_newsindd 14 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 15

ldquoWersquove been steadfast in our posi-tion that deployment of a fuel cell forklift fl eet must be carefully evalu-ated and tested for appropriate use in a warehouserdquo said Jensen ldquoThis research-based approach means that our customers can confi dently know they have the right truck for their chosen fuel cell allowing them to meet their performance safety and

environmental sus-tainability goalsrdquo

Crown continues to work closely with fuel cell manufactur-ers and customers to qualify trucks as new fuel cell pack models are intro-duced ldquoForklifts are a key early market for fuel cellsrdquo said Lisa Callaghan Jerram senior market analyst for Fuel Cell Today a leading analyst

fi rm providing market-based research on the fuel cell industry ldquoBased on our market research we have found strong growth in this sector in the past three yearsrdquo

Because fuel cell powered electric forklifts give off exhaust in the form of moist warm air IC truck custom-ers are looking to this technology

so they donrsquot have to deal exhaust issues Jensen said Another advan-tage pointed out by Jensen is a fuel cell powered truckrsquos ability to effec-tively operate in a cold environment because they generate their own heat and the power doesnrsquot fall off like a traditional battery

While the upfront hardware cost of fuel cells is more expensive than a traditional battery Jensen pointed out the potential to capture savings in labor battery changes battery rooms and heating and venting With fuel cells he said a facility doesnrsquot need a battery room and all that goes in to running it properly Instead there is an ongoing savings associated to using fl oor space for production or other value-added operations

ldquoFuel cells have always been talked about fi ve years into the future but we have customers who are [currently] planning installations around this prod-uctrdquo said Jensen ldquoThe future is hererdquo

Buildings available up to

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property taxes

Call one of our ClearSpan Specialists at 18666431010 or visit us at wwwClearSpancom Mention code CST1109

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Subject to credit approval

To qualify a fuel cell pack and truck combination engineers

review key performance metrics

mmh1010_newsindd 15 101310 1049 AM

lift truck TIPS

GraphicCaption

In the right application tuggers and carts can be a fast and efficient solution

Level the playing field

Football season is under-way and fans are hoping for breakout performances

from stars and rookies alike On the gridiron an overpowered player can be a distinct advan-tage In the warehouse how-ever too much power can lead to waste danger and sluggish performance For some corpo-rations this fact has prompted consideration of fork-free envi-ronments where versatile and custom-built carts and tuggers can do the work faster and more efficiently than their big-ger cousins

Disposing of expensive and powerful equipment in favor of carts may seem counter-intuitive but Jill Burrow marketing manager for Topper Industrial says certain warehouses might benefit greatly from the switch For operations requiring multiple trips between the same areas carts can cut travel time sig-nificantly According to Ed Brown president of Topper Industrial a tugger can pull as many as 13 carts In addi-tion says Brown carts and tuggers can be easier to use than many forklifts

ldquoA forklift costs five times as much but a forklift opera-tor also costs five times more than a tugger operatorrdquo says Brown ldquoAnyone can grab a tugger and gordquo

Once a forklift drops off a pallet in many cases a picker must bend to access product or arrange for the pallet to be lifted Carts on the other hand can be configured with swiveling or angled platforms to allow pickers fast and comfortable access to products Worker safety issues tied to forklifts that operate in tight areas such as poor visibility when driving in re-verse and dock mishaps can also be greatly reduced

ldquoCompanies looking at carts are looking at the cost of equipment and the cost of maintenance but theyrsquore also looking at safetyrdquo says Brown

In addition to ergonomics and safety a fork-free zone might help a warehouse reduce product loss and equip-ment damage Carts provide a secure cradle for moving product while some fork-borne loads are prone to top-pling And forklifts often 10 times as heavy as a tugger and cart setup have a way of proving their strength by leaving dings and dents on storage racks and other hap-less stationary objects

With carts and tuggers Brown says most companies see a return on investment within a year In football a first-round draft pick can cost millions over a multi-year contract before he produces the desired results For com-panies not looking to attempt such a Hail Mary tuggers could prove an efficient alternative

Josh Bond is a contributing editor to Modern and can be reached at turbobondgmailcom

16 O c t O b e r 2 0 1 0 Modern Materials Handling m m h c o m

lift truck TIPS

By Josh Bond Contributing Editor

MMH1010_LiftTruckTipsindd 16 101310 942 AM

MM100601Adsindd 3 6310 349 PMMMH1010_Adsindd 17 101210 1053 AM

18 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

Keith arntson vice president of distribution operations for

del Monte Foods

Four conveyor-topped vehicles ferry loads from an adjacent manufacturing plant

MMH1010_SystemRptDelMonteindd 18 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

bull Discover the newest robotics products and services bull See the latest robot-based solutions for picking and palletizing bull Understand how intelligent robots are revolutionizing processing

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ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

Denso RoboticsElite EngineeringFANUC RoboticsFood EngineeringGenesis Systems GroupHartness InternationalKIva Systems

Modern Materials HandlingMotion Control RoboticsNational InstrumentsOmron Scientifi c Technologies IncRobotics TrendsWind RiverYaskawa Motoman Robotics

MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

chepcomsimplechoice

Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 7: Modern Materials Handling - October 2010

Introducing the new Automatic Destratification System

Big Ass Fans have always saved money in the winter but now it can be done with the push of a button The patent pending Automatic Destratification System keeps your space at the perfect temperature year-round from floor to ceiling The Automatic Destratification System calculates the floor-to-ceiling temperature differential and modulates the fanrsquos speed so you donrsquot have to

Bottom line you could save up to 30 on your heating bills this winterhellip and next winterhellip and next winterhellip

pending Automatic Destratification System keeps your space

Bottom line you could save up to 30 on your heating bills

NEWNEWNEW

Visit wwwBigAssFanscom or call 877-BIG FANS (877-244-3267) to learn moreAn ISO 90012008 certified company

If global warming doesnrsquot reduce your energy costs this winter perhaps we can help

Covered by one or more of the following US Patents 6244821 6589016 6817835 6939108 7252478 7284960 7654798 D587799 D607988 and other patents pending

10 year parts 1 year labor warranty certain exclusions apply See complete warranty for details copy 2010 Delta T Corporation dba The Big Ass Fan Company All rights reserved

BAF_MMH_DestratAd_091610indd 1 91710 851 AMMMH1010_Adsindd 6 101210 1053 AM

EDITORIAL OFFICES111 Speen Street Suite 200Framingham MA 01701-1496(800) 375-8015

Michael LevansGROUP EDITORIAL DIRECTOR mlevansehpubcom

Bob TrebilcockEXECUTIVE EDITOR

roberttrebilcockmyfairpointnet

Noeumll P BodenburgEXECUTIVE MANAGING EDITOR

nbodenburgehpubcom

Lorie King RogersASSOCIATE EDITOR

lrogersehpubcom

Sara Pearson SpecterEDITOR AT LARGE

saramoxiemarketingllccom

Roberto MichelEDITOR AT LARGE

robertomichelnewrrcom

Tom AndelCOLUMNIST

tandel4315aolcom

Jeff BermanGROUP NEWS EDITOR

jbermanehpubcom

Josh BondCONTRIBUTING EDITOR

turbobondgmailcom

Mike RoachCREATIVE DIRECTOR

mroachehpubcom

Wendy DelCampoART DIRECTOR

wdelcampoehpubcom

Daniel GuideraILLUSTRATION

danieldanielguideracom

Brian CeraoloGROUP PUBLISHER bceraoloehpubcom

EDITORIAL ADVISORY BOARD

Ron Giuntini OEM PRODUCT-SERVICES INSTITUTE

John HillESYNC

TRANSYSTEMS

Susan RiderRIDER amp ASSOCIATES

Ken RuehrdanzDEMATIC

Dr John Usher UNIVERSITY OF LOUISVILLE

Col Alan B Will2D MARINE LOGISTICS GROUP

Brett WoodTOYOTA MATERIAL HANDLING USA

Peerless Media LLCA DIVISION OF EH PUBLISHING INC

Kenneth MoyesPRESIDENT AND CEOEH PUBLISHING INC

Brian CeraoloPUBLISHER AND EXECUTIVE VICE PRESIDENT

PEERLESS MEDIA LLC

MAGAZINE SUBSCRIPTIONSStart renew or update your FREE magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPhone 1-800-315-1578Mail Peerless Media PO Box 1496 Framingham MA 01701

eNEWSLETTER SUBSCRIPTIONSSign up or manage your FREE eNewsletter subscriptions at wwwmmhcomenewsletters

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 7

reg

Member Member ofOfficial Publication of

Winner Jesse H Neal

Certificates of Merit for Journalistic

Excellence

EDITORIAL OFFICES111 Speen Street Suite 200Framingham MA 01701-1496(800) 375-8015

Michael LevansGROUP EDITORIAL DIRECTOR mlevansehpubcom

Bob TrebilcockEXECUTIVE EDITOR

roberttrebilcockmyfairpointnet

Noeumll P BodenburgEXECUTIVE MANAGING EDITOR

nbodenburgehpubcom

Lorie King RogersASSOCIATE EDITOR

lrogersehpubcom

Jeff BermanGROUP NEWS EDITOR

jbermanehpubcom

Sara Pearson SpecterEDITOR AT LARGE

saramoxiemarketingllccom

Roberto MichelEDITOR AT LARGE

robertomichelnewrrcom

Josh BondCONTRIBUTING EDITOR

turbobondgmailcom

Mike RoachCREATIVE DIRECTOR

mroachehpubcom

Wendy DelCampoART DIRECTOR

wdelcampoehpubcom

Daniel GuideraILLUSTRATION

danieldanielguideracom

Brian CeraoloGROUP PUBLISHER bceraoloehpubcom

EDITORIAL ADVISORY BOARD

Ron Giuntini OEM PRODUCT-SERVICES INSTITUTE

John HillESYNC

TRANSYSTEMS

Susan RiderRIDER amp ASSOCIATES

Ken RuehrdanzDEMATIC

Dr John Usher UNIVERSITY OF LOUISVILLE

Col Alan B Will2D MARINE LOGISTICS GROUP

Brett WoodTOYOTA MATERIAL HANDLING USA

Peerless Media LLCA DIVISION OF EH PUBLISHING INC

Kenneth MoyesPRESIDENT AND CEOEH PUBLISHING INC

Brian CeraoloPUBLISHER AND EXECUTIVE VICE PRESIDENT

PEERLESS MEDIA LLC

MAGAZINE SUBSCRIPTIONSStart renew or update your FREE magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPhone 1-800-315-1578Mail Peerless Media PO Box 1496 Framingham MA 01701

eNEWSLETTER SUBSCRIPTIONSSign up or manage your FREE eNewsletter subscriptions at wwwmmhcomenewsletters

MICHAEL LEVANSGROUP EDITORIAL

DIRECTOR

THIS MONTH IN MODERN

While it may be at a much slower pace than predicted growth is actually taking place whether

yoursquore feeling it or not In fact we kick off this monthrsquos issue with the latest report from the Material Handling Industry of America that forecasts equipment orders to grow 12 to 14 in 2010 if the current momen-tum persists (page 9)

Mind you those new numbers are com-ing off 2009 when orders saw a 343 de-cline from 2008 But any way we position the latest forecast we canrsquot help but see it as positive news for the industry overall It may even help to crack a few smiles

But while numbers donrsquot lie they can of-ten be deceiving Even though it appeared that equipment orders fell off a cliff two years ago that didnrsquot mean that materials handling professionals went into hiberna-tion in terms of executing improvement projects

In his thoughtful wrap up of HK Systemsrsquos recent Material Handling and Logistics Con-ference (page 10) executive editor Bob Tre-bilcock recounts a number of conversations that he had with attendees who were eager to share the details of the projects that they completed over the past 18 months or moved to the front burner over the past six months There was a local authority looking to put in a new ASRS the Federal Reserve Bank was investigating storage systems and even a specialty foods manufacturer looking to expand a fl eet of AGVs

ldquoI donrsquot think companies plan multi-million dollar investments in automation if

they think the apocalypse is right around the cornerrdquo observes Trebilcock

My fi rm belief that innovation never goes out of stylemdashno matter what the economic environment may bemdashhas been further validated in the system reports that have graced Modernrsquos covers over the past two years Offi ce Depot Kroger Crate amp Barrel Patagonia Bon-Ton Stores The Ap-parel Group IKEAhellipand the list goes on Each of these innovation mavericks has put precious time and strategic thought into materials handling projects that will put them in a distinct competitive advantage as the economic fog begins to clear

Itrsquos safe to say that the brutal economy never once stopped Keith Arntson vice president of distribution operations for Del Monte Foods from thinking how to he could help take miles out of the food giantrsquos distribution network by applying a few new innovations inside his To-peka Kan DC In fact after reading this monthrsquos System Report (page 18) you can say that Arntson has fl ipped over a few materials handling axioms en route to a stunning success

This month Irsquom going to leave Modern readers with a challenge After reading the Del Monte success story Irsquod like you to share with us a few of the innovation projects that yoursquove conducted during the past 18 months We believe that innovation never goes out of style now help us spread the good word and inspire a few of the late adopters Please send me an email on your better idea(s) mlevansehpubcom

Innovation never goes out of style

MMH1010_Editorialindd 7 101310 254 PM

Modern Materials Logistics Management Supply Chain Management

bull Automation

bull Conveyors amp Sorters

bull Inventory amp Picking

bull Loading Dock Equipment

bull Mobile amp Wireless

bull Shipping Pallets

bull Storage Systems

bull Containers amp Totes

bull Energy amp Sustainability

bull Lift Truck amp Fork Lift

bull Handling amp Warehouse Ergonomics

bull Packaging

bull Software amp Technology

wwwmmhcomcriticaltopics

Critical Industry News at Your Fingertips

Critical Topic areas help you develop strategies and expand your knowledge Each topic provides you with the news information and resources you need mdash each day

CRITICAL TOPICS

Modern Materials Logistics Management Supply Chain Management

MMH_CriticalTopics_Houseindd 1 81010 117 PMMMH1010_Adsindd 8 101210 1053 AM

ITrsquoS STILL A FAR CRY FROM 2007 but the materials handling industry is growing once again Following a 343 decline in equipment orders in 2009 the Material Handling Industry of America (MHIA wwwmhiaorg) is forecasting equipment orders to grow 12 to 14 in 2010 if the current momentum continues

A variety of factors are driving growth in manufacturing warehous-ing and distribution on a global basis especially an increase in industrial pro-duction in the fi rst half of 2010 despite factory utilization rates that remain very low by historical comparison

ldquoConsumer demand has not returnedrdquo Hal Vandiver executive vice president of business develop-ment for MHIA told Modern during the associationrsquos fall meeting ldquoBut in the fi rst two quarters the economy shifted from recession into recovery mode fi lling supply chain pipelines re-establishing inventories and re-sponding to pent up demandrdquo

While Vandiver expects the indus-try to continue to grow by 11 to 12 in 2011 drags on the economy continue ldquoForecasts are now calling for a combination of reduced GDP corporate profi t business investment and output growth with industrial utilization remaining below 75 until

late 2011rdquo Vandiver said ldquoThis is largely due to uncertainty Consumers inves-tors and business owners need greater confi dence in the economyrsquos ability to sustain positive growthrdquo For those reasons Vandiver doesnrsquot expect a signifi cant return to the kinds of num-bers the industry posted in the past up until 2007

In addition to

a growth in orders for new equipment Van-diver forecasts material handling shipments to grow 3 to 4 in 2010 and another 10 to 11 in 2011 Domestic demand defi ned as shipments plus imports less exports will grow by 1 in 2010 and by 10 to 11 in 2011 Exports will be stronger than im-ports in 2010 and 2011 refl ecting stronger indus-trial growth in emerging markets outside North America

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 9

Company Briefi ngs | Bob Trebilcock

The age of automationExpressed as an equation The industrial age + the information age = the automation age

mmhcomblogsautomation

Diblogbest of Modernrsquos blogs

BY BOB TREBILCOCK EXECUTIVE EDITOR

ECONOMY

MHIA Growth is backMHIA FORECASTS 12 TO 14 GROWTH IN NEW EQUIPMENT ORDERS IN 2010

0

-343

2009 2010

130(forecast)

MHIA equipment orders forecast

Source Material Handling Industry of America (MHIA)

HIGHJUMP SOFTWARE announced today that it has reached agreement to acquire TrueCommerce a provider of business-to-business integration solutions TrueCommerce provides a comprehensive end-to-end suite of trading partner connectivity solutions including electronic data interchange (EDI) translation and data mapping software transaction network and on-boarding services HighJump Software (wwwhighjumpcom) ranks

No 11 on Modernrsquos 2010 Supply Chain Management Software an-nual list with $85 million in revenue TrueCommercersquos solutions enable trading partner connectivity for 3000 customers feature predefi ned inte-gration to many major ERP systems and can be deployed in either SaaS or on-premise models

The TrueCommerce trading part-ner integration solution complements HighJump Softwarersquos existing supply

MampA

HighJump to acquire TrueCommerce

mmh1010_newsindd 9 101310 1049 AM

middot Robotic palletizing cells handle goods at the end of the production linemiddot LGVs transport pallets to stretch wrapping and labelingmiddot LGVs transport finished pallets to the warehousemiddot LGVs for Storage amp Retrieval (SRS)middot LGVs for Auto-Trailer Loading (ATL)middot An integrated software management system

Elettric 80 is a global provider of end-of-lineautomation solutions These solutions are called Freewayreg material handling system

The technologies are adaptable and have a high degree of built-in flexibility which makes them suitable for any plant warehouse layout or design More details explanatory videos and animations can be found at wwwelettric80com

ITALY middot USA middot SWEDEN middot UK middot AUSTRALIA middot POLAND

Elettric 80 Inc8100 Monticello AvenueSkokie IL 60076 USAPhone +1 847 329 7717e80usaelettric80it

Freewayreg is based on a simple idea

C

M

Y

CM

MY

CY

CMY

K

el80_US_verticalpdf 1 2010-09-29 1346

chain application suite which spans from supplier to store shelf and includes warehouse management systems transportation management systems route accounting systems manufacturing execution mobile sales and ERP data collection Trading partner collaboration is increas-ingly important as organizations strive to reduce costs and improve service levels By combining integration solutions with application functionality organizations are able to ensure consistency in business processes and accuracy of information exchanged with trading partners

ldquoTrueCommerce has fi lled a unique need in the market for simple robust and affordable EDI solutions for small and midsized businessesrdquo said Nick Manolis TrueCom-merce CEO ldquoI am excited for the TrueCommerce team to join HighJump while continuing to provide excellent service support and product innovation to our customersrdquo

ldquoCombining HighJump and TrueCommerce creates a unique and compelling solution offering within the supply chain software marketrdquo said Russell Fleischer HighJump Software CEO ldquoOur view is that supply chain applications must allow users to connect with a broad ecosystem of trading partners to maximize value The TrueCommerce solution platform and our previous move to cloud-based applications will help translate this vision into reality for our customersrdquo

SUPPLY CHAIN NEWS ANALYSIS

Final thoughts on Supply Chain Reset conferenceBY BOB TREBILCOCK EXECUTIVE EDITOR

DESPITE SIGNS OF IMPROVEMENTS doing business in in materials handling remains a challenge At the same time many of the leading customers are investing in supply chain software and automated materials handling systems to improve their businesses That suggests better times are coming

Tom Brokaw punctuates the 25th anniversary of the Material

Handling and Logistics Conference by HK Systems

mmh1010_newsindd 10 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 11

Leader of the PackThe originator of high speed narrow belt sortationTGW Systems has led the way in offering provenadvantages over conventional sortation for over 10 years

NBS fromTGW Systems

50 less install time60 less energy75 less noise

100 of the Value

wwwtgw-groupcom

TGW Systems (formerly TGW-Ermanco) is an integrated logistics solutions and material handling equipment provider The Ermanco name lives onas the product family name for the conveying andsortation products manufactured in the US

Our worldwide perspective and resources and commitment to innovation product developmentand unparalleled customer service can help you today

Proven track record ndash Over 700 installations around the world have made TGWrsquos Narrow Belt Sorter one of the most reliable sorters available

Rugged durability ndash TGWrsquos NBS sorters operate in some of the harshest distribution environments in the world earning customerrsquos admiration and competitorrsquos respect

Application and layout fl exibility ndash The universal frame on TGWrsquos narrow belt sorter means you can use multiple divert options and easily add divert modules after installation for increased fl exibility

Patented technology ndash Patented sortation technology in the TGWrsquos narrow belt sorter continues to lead the way in effective energy effi cient fl exible sortation

10 08 NBSindd 1 8302010 34008 PM

keep enough labor to run his primary distribution center Two presentations drove this point home The fi rst was from an executive with Tim Hor-tons the Dunkin Donuts of Canada The companyrsquos beautiful new DC in Guelph Ontario is underperforming projections even though the ASRS is

living up to its promises The reason The company canrsquot fi nd enough labor willing to work in its case picking and palletizing operations The other was by Terra Winston a consultant who presented a case study about a proj-ect at PepsiCo to develop the next wave of supply chain leaders Her

Those are the two high level take-aways from Supply Chain Reset the annual logistics conference held last month in Park City Utah sponsored by HK Systems now part of Dematic

ldquoLousyrdquo was the most common response to the dinner-time question ldquoHowrsquos businessrdquo

At the same time the roll call of end user companies that said they had projects in the works or on the drawing board was both a Whorsquos Who of American business with names like Coca-Cola and Kraft and companies many of us may never have heard of or think of as custom-ers of our solutions For example I sat on the van from the airport with a guy from the Los Angeles metro-politan transportation system looking for a new automated storage and retrieval system (ASRS) The Federal Reserve Bank was there investigat-ing storage systems I rode in the van back to the airport with a woman from a producer of honey in Texas who had both an ASRS and auto-matic guided vehicles in her facil-ity and was looking to expand her system

Those are signs of a growing con-fi dence I donrsquot think companies plan multi-million dollar investments in au-tomation if they think the apocalypse is right around the corner

One other anecdotal data point Marc Ducharme a vice president and partner with Axium a supplier of robotic materials handling solu-tions told me that 2009 was a dismal year for implementations but that his company has been swamped with RFPs in 2010 An RFP is not an order but itrsquos a sign

A few other observationsRetaining labor and talent could

be the most important issue facing the industry in the future A week or so before going to Utah I had a con-versation with a vice president of sup-ply chain for a major retailer who told me he is interested in automation because he simply cannot fi nd and

mmh1010_newsindd 11 101310 1049 AM

12 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

point the talent shortage isnrsquot limited just to the shop fl oor

Retrofi tting is a viable solution You know the old saying Every-thing old is new again Wegmanrsquos a Midwestern grocer and Rubber-maid both gave strong presenta-tions about how they replaced ag-ing ASRS cranes to breathe new life into their DCs Meanwhile Anheuser Busch gained new ef-fi ciencies in its Columbus Ohio facility by upgrading a warehouse control system

Everyone loves pallets Based in Iowa Green Line Armor is offering a heavy-duty hybrid woodplastic pallet for permanent pallet pools The 48- x 40-inch pallet has heavier stringers and more deck board coverage than a grocery pallet The lead boards on the top and the bottom of the palletmdashthose most likely to get damaged by a lift truckmdashare manufactured from heavy plastic The pallet has a passive RFID

tag that is used by Green Line Armor to identify the pallet and manage war-ranty services Active RFID tags were installed for John Deere the companyrsquos largest customer to track the location of work in process stored on the pallets between manufacturing processes Eric Renteria the companyrsquos president said the pallets which come with a 10-year warranty can be purchased or leased

in a pooling modelNew players are get-

ting into automation Kip Tygard whose company makes the Tygard Claw a lift truck attachment for mixed case palletizing is investing RampD money to develop an automated version of the Claw Thatrsquos not a big shock Tygard is an OEM But I also had conversations with two very large end users in the wholesale food distribu-

tion business that have designed their own automated systemsmdashone has built and implemented its own ASRS design for freezers for years the other has designed its own case picking application that it intends to put out for bid to the materials handling community Both say they may commercialize their solutions in the future

VERSATILITY MATTERSQuality Wildeck construction and versatility make the V-lifttrade the ultimate lifting solution

In todayrsquos lsquogreenrsquo building designs floor space is at a premium and moving up not out is definitely preferred Look no further than the V-Lifttrade from Wildeck ndash the industry leader in space optimization The single cylinder hydraulic system eliminates all moving hoses cables and chains Fewer components means easy installation reduced maintenance and longer service life To get more value out of your operation contact a Wildeck representative today

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800-325-6939 | WWWWILDECKCOM

MEZZANINESCapacity Matters Efficiency Matters

LIFT SYSTEMSSafety MattersGUARDING PRODUCTS

able to make better decisionsmdashespecially in the case of the unexpected ldquoWhen a shipment is held up at the portrdquo says Prashant Bhatia director of solutions management at SAP ldquoit can trigger logic back to say that Irsquove got a problem I can no longer allocate that inventory on that particular shipment as I thought I couldrdquo

3 One database one system one supply chain In the last few years soft-ware providers have been pulling all of their products onto a single supply chain process platform ldquoItrsquos fairly newrdquo says Lamphier ldquoVarious components have been integrated into that supply chain process platform longer than others but actually moving our WMS onto it has been a more recent developmentmdashjust within the last quarter or twordquo

SAP uses its enterprise resource planning (ERP) system as the central repository of information of supply and demand as well as inventory for the entire supply chain And the modules all

talk to each other Transportation man-agement systems (TMS) in conjunction with the event management modules help optimize freight determine pick-up windows determine carriers keep track of in-transit times and create ASNs

That ASN not only gets sent back to the ERP for visibility but it also gets sent to the WMS where the sys-tem uses the information to plan labor equipment and resources at the receiv-ing dock When the physical product arrives logic within the WMS based on the receipt of goods determines matches against actual demand

Smarter speedier equipment With more retailers crossdocking

over 50 of their items at the case level to their stores equipment innovations have centered on conveyor sortation systems print and apply mechanisms and automatic identifi cation technolo-gies Here are three new equipment

advances1 Smaller gaps and self-regulat-

ing conveyors In the last year the sliding shoe sorter has undergone note-worthy transformations ldquoBy doing a par-allel divert we can now run the packages closer together and get a higher through-put on the same systemrdquo reports Ken Ruehrdanz manager for Dematicrsquos distri-bution and warehousing markets

The sliding shoes that used to physi-cally push the cartons off the sorter at an angle can now run those shoes in parallel enabling smaller gaps between cartonsmdashwhich were previously from 6 inches to 8 inchesmdashdown to 3 inches

With more dense traffi c on conveyors crossdock operators can run their con-veyors at a lower speed while still achiev-ing the same throughput Slower speeds equal less wear and tear decreased energy usage and less maintenance

Another conveyor breakthrough is automatic speed control ldquoThe whole

m m h c o m MODERN MATERIALS HANDLING A P R I L 2 0 1 0 49S

MMH100401sup_Crossdock_ID 49 482010 113620 AM

Leading customers are investing in software and automated

systems to improve business according to attendees of the

Supply Chain Reset conference

mmh1010_newsindd 12 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 13

THE INDUSTRIAL REAL ESTATEmarket is taking steps in the right direction according to a report recently issued by global real estate fi rm Jones Lang LaSalle (JLL wwwjoneslanglasallecom) which report-ed the national average vacancy rate for the North American industrial real estate sector fell from 106 in the fi rst quarter to 104 in the second quarter Despite the slight decline in vacancy the fragile economy still looms large due to declining con-sumer confi dence the drying up of economic stimulus funding and the potential threat of a double-dip recession the report noted

ldquoWe have seen a positive absorp-tion in the vacancy rate in the second quarter but we are very concerned

going forwardrdquo Craig Meyer managing director and leader of JLLrsquos Logistics and Industrial Services Group told Modern ldquoAny kind of sustained demand-driven component in the industrial real estate market is going to be driven by jobs We are just not seeing any of that It is going to be a long slow recoveryrdquo

Looking at base indicators like the Institute of Supply Managementrsquos Manufacturing Index Consumer Confi dence data and industrial real estate vacancy and absorption rates there does not appear to be what Meyer labeled as a strong indication of a positive upswing on the horizon

The report says that a need to restock inventories that were running at 50-year lows resulted in large com-panies strategically capturing high

quality logistics space at cyclically low rates And with slow levels of leasing activity and sparse construc-tion industrial real estate optionsmdashespecially in the Class A large block sectormdashare limited in some markets

And the swift correction in invento-ries during the second half of 2009 and fi rst quarter of 2010 has left inventory levels lean and ready for expansion provided sales rebound in the coming months Should this occur it could lead to increased industrial and logistics real estate leasing activity

The report also pointed out that the initial recovery in the economy was largely driven by improvements in the manufacturing sector and cyclical adjustments in inventories But with the recovery now becoming more broad-based the recent slowdown of inven-tory building could have more of an impact on the industrial property sector than the offi ce sector the report noted

Date 090910 Client Rehrig Pacifi c Job 08312010 File Name 0831_RPC_SlipSheet_Ad_MMH_Oct10 Round

Account Director Niki Phan Designer Revised By ov Editor Production ov

Color 4CProcess Trim 7 times 4625 Bleed 0 Safety 675times 4375 Fold na

Publication(s) TBD Run Date(s) TBD

Approved By

A FAMILY TRADITION OF GROWTH SERVICE AND INNOVATION

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Available in standard or custom sizes with a variety of surface textures and embossed patterns Rehrig Slip Sheets provide superior slide resistance keeping goods securely in place Manufactured from nearly 100 recycled material each sheet is also 100 recyclable

Beyond the sale Rehrig can help you develop a customized re-use or buy-back program further lowering your average cost per trip

Phone (800) 546-4993 Email inforehrigpacificcom Web wwwrehrigpacificcom

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WAREHOUSESDCS

Industrial real estate market making progress challenges remain

mmh1010_newsindd 13 101310 1049 AM

14 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

ldquoWe are also concerned about seasonality with the holiday season coming uprdquo said Meyer ldquoThe indica-tions we are getting are that we may not see as much preparation for that as we hoped A lot of retailers are saying they are restocked and if consumer confi dence is going down they are not going to build up inventories And for larger big box companies they will see declining values in rents but the availability of product for them to lease is diminishingrdquo

As a result Class A big box dis-tribution space is becoming more diffi cult to fi nd in this economy said Meyer But the build-to-suit market could come back for major retailers as evidenced by a new 1-million-square-foot DC space deal by Amazoncom in Harrisburg Pa and a 14-million-square-foot location in Phoenix

But for a mid-sized industrial building in the 100000-to-150000-square-foot range Class B-sized build-

ing Meyer said there are an infi nite number of these on the market

Looking ahead Meyer said there will still be downward pressure on pric-

ing a double-digit vacancy rate and no increases in lease rates which he noted are actually weakening a little bit and tend to lag a recovery

Power AND CoNtrol

Introducing the latest innovations for incorporating Power AND Control into

your 24 VDC conveyor system

For over 60 years Itoh Denki has been the proven leader in the development and manufacture of superior motorized rollers and components This history provides you confidence in your 24V conveyor applications and designs a confidence based on the component integrity offered by the only sole source motor and control manufacturer in the industry

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Intelligent solutions yoursquod expect from Itoh Denki Intelligent solutions yoursquod expect from Itoh Denki

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LIFTrdquoBFL lifts are designed to move large loads ormultiple pallets betweenfloors These lifts willtravel from 8 feet to 18feet and have platformsizes ranging from 6rsquo x 8rsquo up to 8rsquo x 12rsquoThey are ideal for movinglarge loads 1-2 floors orup to high stages andmezzanines

1-800-843-3625wwwadvancel i f ts com

BFL AD MMH APRIL 92710 358 PM Page 1

CROWN EQUIPMENT Corp has quali-fi ed 20 of its electric models to operate with various fuel cells bringing the total of qualifi ed combinations of fuel cell packs and trucks to 29 In 2009 Crown (wwwcrowncom) was the fi rst lift truck manufacturer to introduce a fuel cell qualifi cation program

Eric Jensen Crownrsquos manager of new technology research and de-velopment told Modern that the companyrsquos fuel cell qualifi cation pro-gram duplicates its own testing and is conducted at a 25000-square-foot research facility near Dayton Ohio Through the testing process engi-

neers evaluate fuel cell performance and monitor whether issues develop that affect the truckrsquos operation

To qualify a fuel cell pack and truck combination Crownrsquos engineers review key performance metrics for a battery-powered truck such as traction plug-ging and lift and travel speeds Then they replace the battery with a fuel cell power pack and measure the same indicators Through modeling and ap-plication testing the research team de-termines design modifi cations needed to ensure the fuel cell-powered forklift matched standards to which the truck was designed

LIFT TRUCKS

Crown unveils 20 electric lift trucks to operate with fuel cells

mmh1010_newsindd 14 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 15

ldquoWersquove been steadfast in our posi-tion that deployment of a fuel cell forklift fl eet must be carefully evalu-ated and tested for appropriate use in a warehouserdquo said Jensen ldquoThis research-based approach means that our customers can confi dently know they have the right truck for their chosen fuel cell allowing them to meet their performance safety and

environmental sus-tainability goalsrdquo

Crown continues to work closely with fuel cell manufactur-ers and customers to qualify trucks as new fuel cell pack models are intro-duced ldquoForklifts are a key early market for fuel cellsrdquo said Lisa Callaghan Jerram senior market analyst for Fuel Cell Today a leading analyst

fi rm providing market-based research on the fuel cell industry ldquoBased on our market research we have found strong growth in this sector in the past three yearsrdquo

Because fuel cell powered electric forklifts give off exhaust in the form of moist warm air IC truck custom-ers are looking to this technology

so they donrsquot have to deal exhaust issues Jensen said Another advan-tage pointed out by Jensen is a fuel cell powered truckrsquos ability to effec-tively operate in a cold environment because they generate their own heat and the power doesnrsquot fall off like a traditional battery

While the upfront hardware cost of fuel cells is more expensive than a traditional battery Jensen pointed out the potential to capture savings in labor battery changes battery rooms and heating and venting With fuel cells he said a facility doesnrsquot need a battery room and all that goes in to running it properly Instead there is an ongoing savings associated to using fl oor space for production or other value-added operations

ldquoFuel cells have always been talked about fi ve years into the future but we have customers who are [currently] planning installations around this prod-uctrdquo said Jensen ldquoThe future is hererdquo

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Call one of our ClearSpan Specialists at 18666431010 or visit us at wwwClearSpancom Mention code CST1109

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Subject to credit approval

To qualify a fuel cell pack and truck combination engineers

review key performance metrics

mmh1010_newsindd 15 101310 1049 AM

lift truck TIPS

GraphicCaption

In the right application tuggers and carts can be a fast and efficient solution

Level the playing field

Football season is under-way and fans are hoping for breakout performances

from stars and rookies alike On the gridiron an overpowered player can be a distinct advan-tage In the warehouse how-ever too much power can lead to waste danger and sluggish performance For some corpo-rations this fact has prompted consideration of fork-free envi-ronments where versatile and custom-built carts and tuggers can do the work faster and more efficiently than their big-ger cousins

Disposing of expensive and powerful equipment in favor of carts may seem counter-intuitive but Jill Burrow marketing manager for Topper Industrial says certain warehouses might benefit greatly from the switch For operations requiring multiple trips between the same areas carts can cut travel time sig-nificantly According to Ed Brown president of Topper Industrial a tugger can pull as many as 13 carts In addi-tion says Brown carts and tuggers can be easier to use than many forklifts

ldquoA forklift costs five times as much but a forklift opera-tor also costs five times more than a tugger operatorrdquo says Brown ldquoAnyone can grab a tugger and gordquo

Once a forklift drops off a pallet in many cases a picker must bend to access product or arrange for the pallet to be lifted Carts on the other hand can be configured with swiveling or angled platforms to allow pickers fast and comfortable access to products Worker safety issues tied to forklifts that operate in tight areas such as poor visibility when driving in re-verse and dock mishaps can also be greatly reduced

ldquoCompanies looking at carts are looking at the cost of equipment and the cost of maintenance but theyrsquore also looking at safetyrdquo says Brown

In addition to ergonomics and safety a fork-free zone might help a warehouse reduce product loss and equip-ment damage Carts provide a secure cradle for moving product while some fork-borne loads are prone to top-pling And forklifts often 10 times as heavy as a tugger and cart setup have a way of proving their strength by leaving dings and dents on storage racks and other hap-less stationary objects

With carts and tuggers Brown says most companies see a return on investment within a year In football a first-round draft pick can cost millions over a multi-year contract before he produces the desired results For com-panies not looking to attempt such a Hail Mary tuggers could prove an efficient alternative

Josh Bond is a contributing editor to Modern and can be reached at turbobondgmailcom

16 O c t O b e r 2 0 1 0 Modern Materials Handling m m h c o m

lift truck TIPS

By Josh Bond Contributing Editor

MMH1010_LiftTruckTipsindd 16 101310 942 AM

MM100601Adsindd 3 6310 349 PMMMH1010_Adsindd 17 101210 1053 AM

18 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

Keith arntson vice president of distribution operations for

del Monte Foods

Four conveyor-topped vehicles ferry loads from an adjacent manufacturing plant

MMH1010_SystemRptDelMonteindd 18 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

bull Discover the newest robotics products and services bull See the latest robot-based solutions for picking and palletizing bull Understand how intelligent robots are revolutionizing processing

packaging plant operations and material handling bull Learn about robotics solutions that will increase your bottom line

Sponsoring companies include

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ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

Denso RoboticsElite EngineeringFANUC RoboticsFood EngineeringGenesis Systems GroupHartness InternationalKIva Systems

Modern Materials HandlingMotion Control RoboticsNational InstrumentsOmron Scientifi c Technologies IncRobotics TrendsWind RiverYaskawa Motoman Robotics

MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

chepcomsimplechoice

Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

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SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 8: Modern Materials Handling - October 2010

EDITORIAL OFFICES111 Speen Street Suite 200Framingham MA 01701-1496(800) 375-8015

Michael LevansGROUP EDITORIAL DIRECTOR mlevansehpubcom

Bob TrebilcockEXECUTIVE EDITOR

roberttrebilcockmyfairpointnet

Noeumll P BodenburgEXECUTIVE MANAGING EDITOR

nbodenburgehpubcom

Lorie King RogersASSOCIATE EDITOR

lrogersehpubcom

Sara Pearson SpecterEDITOR AT LARGE

saramoxiemarketingllccom

Roberto MichelEDITOR AT LARGE

robertomichelnewrrcom

Tom AndelCOLUMNIST

tandel4315aolcom

Jeff BermanGROUP NEWS EDITOR

jbermanehpubcom

Josh BondCONTRIBUTING EDITOR

turbobondgmailcom

Mike RoachCREATIVE DIRECTOR

mroachehpubcom

Wendy DelCampoART DIRECTOR

wdelcampoehpubcom

Daniel GuideraILLUSTRATION

danieldanielguideracom

Brian CeraoloGROUP PUBLISHER bceraoloehpubcom

EDITORIAL ADVISORY BOARD

Ron Giuntini OEM PRODUCT-SERVICES INSTITUTE

John HillESYNC

TRANSYSTEMS

Susan RiderRIDER amp ASSOCIATES

Ken RuehrdanzDEMATIC

Dr John Usher UNIVERSITY OF LOUISVILLE

Col Alan B Will2D MARINE LOGISTICS GROUP

Brett WoodTOYOTA MATERIAL HANDLING USA

Peerless Media LLCA DIVISION OF EH PUBLISHING INC

Kenneth MoyesPRESIDENT AND CEOEH PUBLISHING INC

Brian CeraoloPUBLISHER AND EXECUTIVE VICE PRESIDENT

PEERLESS MEDIA LLC

MAGAZINE SUBSCRIPTIONSStart renew or update your FREE magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPhone 1-800-315-1578Mail Peerless Media PO Box 1496 Framingham MA 01701

eNEWSLETTER SUBSCRIPTIONSSign up or manage your FREE eNewsletter subscriptions at wwwmmhcomenewsletters

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 7

reg

Member Member ofOfficial Publication of

Winner Jesse H Neal

Certificates of Merit for Journalistic

Excellence

EDITORIAL OFFICES111 Speen Street Suite 200Framingham MA 01701-1496(800) 375-8015

Michael LevansGROUP EDITORIAL DIRECTOR mlevansehpubcom

Bob TrebilcockEXECUTIVE EDITOR

roberttrebilcockmyfairpointnet

Noeumll P BodenburgEXECUTIVE MANAGING EDITOR

nbodenburgehpubcom

Lorie King RogersASSOCIATE EDITOR

lrogersehpubcom

Jeff BermanGROUP NEWS EDITOR

jbermanehpubcom

Sara Pearson SpecterEDITOR AT LARGE

saramoxiemarketingllccom

Roberto MichelEDITOR AT LARGE

robertomichelnewrrcom

Josh BondCONTRIBUTING EDITOR

turbobondgmailcom

Mike RoachCREATIVE DIRECTOR

mroachehpubcom

Wendy DelCampoART DIRECTOR

wdelcampoehpubcom

Daniel GuideraILLUSTRATION

danieldanielguideracom

Brian CeraoloGROUP PUBLISHER bceraoloehpubcom

EDITORIAL ADVISORY BOARD

Ron Giuntini OEM PRODUCT-SERVICES INSTITUTE

John HillESYNC

TRANSYSTEMS

Susan RiderRIDER amp ASSOCIATES

Ken RuehrdanzDEMATIC

Dr John Usher UNIVERSITY OF LOUISVILLE

Col Alan B Will2D MARINE LOGISTICS GROUP

Brett WoodTOYOTA MATERIAL HANDLING USA

Peerless Media LLCA DIVISION OF EH PUBLISHING INC

Kenneth MoyesPRESIDENT AND CEOEH PUBLISHING INC

Brian CeraoloPUBLISHER AND EXECUTIVE VICE PRESIDENT

PEERLESS MEDIA LLC

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MICHAEL LEVANSGROUP EDITORIAL

DIRECTOR

THIS MONTH IN MODERN

While it may be at a much slower pace than predicted growth is actually taking place whether

yoursquore feeling it or not In fact we kick off this monthrsquos issue with the latest report from the Material Handling Industry of America that forecasts equipment orders to grow 12 to 14 in 2010 if the current momen-tum persists (page 9)

Mind you those new numbers are com-ing off 2009 when orders saw a 343 de-cline from 2008 But any way we position the latest forecast we canrsquot help but see it as positive news for the industry overall It may even help to crack a few smiles

But while numbers donrsquot lie they can of-ten be deceiving Even though it appeared that equipment orders fell off a cliff two years ago that didnrsquot mean that materials handling professionals went into hiberna-tion in terms of executing improvement projects

In his thoughtful wrap up of HK Systemsrsquos recent Material Handling and Logistics Con-ference (page 10) executive editor Bob Tre-bilcock recounts a number of conversations that he had with attendees who were eager to share the details of the projects that they completed over the past 18 months or moved to the front burner over the past six months There was a local authority looking to put in a new ASRS the Federal Reserve Bank was investigating storage systems and even a specialty foods manufacturer looking to expand a fl eet of AGVs

ldquoI donrsquot think companies plan multi-million dollar investments in automation if

they think the apocalypse is right around the cornerrdquo observes Trebilcock

My fi rm belief that innovation never goes out of stylemdashno matter what the economic environment may bemdashhas been further validated in the system reports that have graced Modernrsquos covers over the past two years Offi ce Depot Kroger Crate amp Barrel Patagonia Bon-Ton Stores The Ap-parel Group IKEAhellipand the list goes on Each of these innovation mavericks has put precious time and strategic thought into materials handling projects that will put them in a distinct competitive advantage as the economic fog begins to clear

Itrsquos safe to say that the brutal economy never once stopped Keith Arntson vice president of distribution operations for Del Monte Foods from thinking how to he could help take miles out of the food giantrsquos distribution network by applying a few new innovations inside his To-peka Kan DC In fact after reading this monthrsquos System Report (page 18) you can say that Arntson has fl ipped over a few materials handling axioms en route to a stunning success

This month Irsquom going to leave Modern readers with a challenge After reading the Del Monte success story Irsquod like you to share with us a few of the innovation projects that yoursquove conducted during the past 18 months We believe that innovation never goes out of style now help us spread the good word and inspire a few of the late adopters Please send me an email on your better idea(s) mlevansehpubcom

Innovation never goes out of style

MMH1010_Editorialindd 7 101310 254 PM

Modern Materials Logistics Management Supply Chain Management

bull Automation

bull Conveyors amp Sorters

bull Inventory amp Picking

bull Loading Dock Equipment

bull Mobile amp Wireless

bull Shipping Pallets

bull Storage Systems

bull Containers amp Totes

bull Energy amp Sustainability

bull Lift Truck amp Fork Lift

bull Handling amp Warehouse Ergonomics

bull Packaging

bull Software amp Technology

wwwmmhcomcriticaltopics

Critical Industry News at Your Fingertips

Critical Topic areas help you develop strategies and expand your knowledge Each topic provides you with the news information and resources you need mdash each day

CRITICAL TOPICS

Modern Materials Logistics Management Supply Chain Management

MMH_CriticalTopics_Houseindd 1 81010 117 PMMMH1010_Adsindd 8 101210 1053 AM

ITrsquoS STILL A FAR CRY FROM 2007 but the materials handling industry is growing once again Following a 343 decline in equipment orders in 2009 the Material Handling Industry of America (MHIA wwwmhiaorg) is forecasting equipment orders to grow 12 to 14 in 2010 if the current momentum continues

A variety of factors are driving growth in manufacturing warehous-ing and distribution on a global basis especially an increase in industrial pro-duction in the fi rst half of 2010 despite factory utilization rates that remain very low by historical comparison

ldquoConsumer demand has not returnedrdquo Hal Vandiver executive vice president of business develop-ment for MHIA told Modern during the associationrsquos fall meeting ldquoBut in the fi rst two quarters the economy shifted from recession into recovery mode fi lling supply chain pipelines re-establishing inventories and re-sponding to pent up demandrdquo

While Vandiver expects the indus-try to continue to grow by 11 to 12 in 2011 drags on the economy continue ldquoForecasts are now calling for a combination of reduced GDP corporate profi t business investment and output growth with industrial utilization remaining below 75 until

late 2011rdquo Vandiver said ldquoThis is largely due to uncertainty Consumers inves-tors and business owners need greater confi dence in the economyrsquos ability to sustain positive growthrdquo For those reasons Vandiver doesnrsquot expect a signifi cant return to the kinds of num-bers the industry posted in the past up until 2007

In addition to

a growth in orders for new equipment Van-diver forecasts material handling shipments to grow 3 to 4 in 2010 and another 10 to 11 in 2011 Domestic demand defi ned as shipments plus imports less exports will grow by 1 in 2010 and by 10 to 11 in 2011 Exports will be stronger than im-ports in 2010 and 2011 refl ecting stronger indus-trial growth in emerging markets outside North America

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 9

Company Briefi ngs | Bob Trebilcock

The age of automationExpressed as an equation The industrial age + the information age = the automation age

mmhcomblogsautomation

Diblogbest of Modernrsquos blogs

BY BOB TREBILCOCK EXECUTIVE EDITOR

ECONOMY

MHIA Growth is backMHIA FORECASTS 12 TO 14 GROWTH IN NEW EQUIPMENT ORDERS IN 2010

0

-343

2009 2010

130(forecast)

MHIA equipment orders forecast

Source Material Handling Industry of America (MHIA)

HIGHJUMP SOFTWARE announced today that it has reached agreement to acquire TrueCommerce a provider of business-to-business integration solutions TrueCommerce provides a comprehensive end-to-end suite of trading partner connectivity solutions including electronic data interchange (EDI) translation and data mapping software transaction network and on-boarding services HighJump Software (wwwhighjumpcom) ranks

No 11 on Modernrsquos 2010 Supply Chain Management Software an-nual list with $85 million in revenue TrueCommercersquos solutions enable trading partner connectivity for 3000 customers feature predefi ned inte-gration to many major ERP systems and can be deployed in either SaaS or on-premise models

The TrueCommerce trading part-ner integration solution complements HighJump Softwarersquos existing supply

MampA

HighJump to acquire TrueCommerce

mmh1010_newsindd 9 101310 1049 AM

middot Robotic palletizing cells handle goods at the end of the production linemiddot LGVs transport pallets to stretch wrapping and labelingmiddot LGVs transport finished pallets to the warehousemiddot LGVs for Storage amp Retrieval (SRS)middot LGVs for Auto-Trailer Loading (ATL)middot An integrated software management system

Elettric 80 is a global provider of end-of-lineautomation solutions These solutions are called Freewayreg material handling system

The technologies are adaptable and have a high degree of built-in flexibility which makes them suitable for any plant warehouse layout or design More details explanatory videos and animations can be found at wwwelettric80com

ITALY middot USA middot SWEDEN middot UK middot AUSTRALIA middot POLAND

Elettric 80 Inc8100 Monticello AvenueSkokie IL 60076 USAPhone +1 847 329 7717e80usaelettric80it

Freewayreg is based on a simple idea

C

M

Y

CM

MY

CY

CMY

K

el80_US_verticalpdf 1 2010-09-29 1346

chain application suite which spans from supplier to store shelf and includes warehouse management systems transportation management systems route accounting systems manufacturing execution mobile sales and ERP data collection Trading partner collaboration is increas-ingly important as organizations strive to reduce costs and improve service levels By combining integration solutions with application functionality organizations are able to ensure consistency in business processes and accuracy of information exchanged with trading partners

ldquoTrueCommerce has fi lled a unique need in the market for simple robust and affordable EDI solutions for small and midsized businessesrdquo said Nick Manolis TrueCom-merce CEO ldquoI am excited for the TrueCommerce team to join HighJump while continuing to provide excellent service support and product innovation to our customersrdquo

ldquoCombining HighJump and TrueCommerce creates a unique and compelling solution offering within the supply chain software marketrdquo said Russell Fleischer HighJump Software CEO ldquoOur view is that supply chain applications must allow users to connect with a broad ecosystem of trading partners to maximize value The TrueCommerce solution platform and our previous move to cloud-based applications will help translate this vision into reality for our customersrdquo

SUPPLY CHAIN NEWS ANALYSIS

Final thoughts on Supply Chain Reset conferenceBY BOB TREBILCOCK EXECUTIVE EDITOR

DESPITE SIGNS OF IMPROVEMENTS doing business in in materials handling remains a challenge At the same time many of the leading customers are investing in supply chain software and automated materials handling systems to improve their businesses That suggests better times are coming

Tom Brokaw punctuates the 25th anniversary of the Material

Handling and Logistics Conference by HK Systems

mmh1010_newsindd 10 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 11

Leader of the PackThe originator of high speed narrow belt sortationTGW Systems has led the way in offering provenadvantages over conventional sortation for over 10 years

NBS fromTGW Systems

50 less install time60 less energy75 less noise

100 of the Value

wwwtgw-groupcom

TGW Systems (formerly TGW-Ermanco) is an integrated logistics solutions and material handling equipment provider The Ermanco name lives onas the product family name for the conveying andsortation products manufactured in the US

Our worldwide perspective and resources and commitment to innovation product developmentand unparalleled customer service can help you today

Proven track record ndash Over 700 installations around the world have made TGWrsquos Narrow Belt Sorter one of the most reliable sorters available

Rugged durability ndash TGWrsquos NBS sorters operate in some of the harshest distribution environments in the world earning customerrsquos admiration and competitorrsquos respect

Application and layout fl exibility ndash The universal frame on TGWrsquos narrow belt sorter means you can use multiple divert options and easily add divert modules after installation for increased fl exibility

Patented technology ndash Patented sortation technology in the TGWrsquos narrow belt sorter continues to lead the way in effective energy effi cient fl exible sortation

10 08 NBSindd 1 8302010 34008 PM

keep enough labor to run his primary distribution center Two presentations drove this point home The fi rst was from an executive with Tim Hor-tons the Dunkin Donuts of Canada The companyrsquos beautiful new DC in Guelph Ontario is underperforming projections even though the ASRS is

living up to its promises The reason The company canrsquot fi nd enough labor willing to work in its case picking and palletizing operations The other was by Terra Winston a consultant who presented a case study about a proj-ect at PepsiCo to develop the next wave of supply chain leaders Her

Those are the two high level take-aways from Supply Chain Reset the annual logistics conference held last month in Park City Utah sponsored by HK Systems now part of Dematic

ldquoLousyrdquo was the most common response to the dinner-time question ldquoHowrsquos businessrdquo

At the same time the roll call of end user companies that said they had projects in the works or on the drawing board was both a Whorsquos Who of American business with names like Coca-Cola and Kraft and companies many of us may never have heard of or think of as custom-ers of our solutions For example I sat on the van from the airport with a guy from the Los Angeles metro-politan transportation system looking for a new automated storage and retrieval system (ASRS) The Federal Reserve Bank was there investigat-ing storage systems I rode in the van back to the airport with a woman from a producer of honey in Texas who had both an ASRS and auto-matic guided vehicles in her facil-ity and was looking to expand her system

Those are signs of a growing con-fi dence I donrsquot think companies plan multi-million dollar investments in au-tomation if they think the apocalypse is right around the corner

One other anecdotal data point Marc Ducharme a vice president and partner with Axium a supplier of robotic materials handling solu-tions told me that 2009 was a dismal year for implementations but that his company has been swamped with RFPs in 2010 An RFP is not an order but itrsquos a sign

A few other observationsRetaining labor and talent could

be the most important issue facing the industry in the future A week or so before going to Utah I had a con-versation with a vice president of sup-ply chain for a major retailer who told me he is interested in automation because he simply cannot fi nd and

mmh1010_newsindd 11 101310 1049 AM

12 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

point the talent shortage isnrsquot limited just to the shop fl oor

Retrofi tting is a viable solution You know the old saying Every-thing old is new again Wegmanrsquos a Midwestern grocer and Rubber-maid both gave strong presenta-tions about how they replaced ag-ing ASRS cranes to breathe new life into their DCs Meanwhile Anheuser Busch gained new ef-fi ciencies in its Columbus Ohio facility by upgrading a warehouse control system

Everyone loves pallets Based in Iowa Green Line Armor is offering a heavy-duty hybrid woodplastic pallet for permanent pallet pools The 48- x 40-inch pallet has heavier stringers and more deck board coverage than a grocery pallet The lead boards on the top and the bottom of the palletmdashthose most likely to get damaged by a lift truckmdashare manufactured from heavy plastic The pallet has a passive RFID

tag that is used by Green Line Armor to identify the pallet and manage war-ranty services Active RFID tags were installed for John Deere the companyrsquos largest customer to track the location of work in process stored on the pallets between manufacturing processes Eric Renteria the companyrsquos president said the pallets which come with a 10-year warranty can be purchased or leased

in a pooling modelNew players are get-

ting into automation Kip Tygard whose company makes the Tygard Claw a lift truck attachment for mixed case palletizing is investing RampD money to develop an automated version of the Claw Thatrsquos not a big shock Tygard is an OEM But I also had conversations with two very large end users in the wholesale food distribu-

tion business that have designed their own automated systemsmdashone has built and implemented its own ASRS design for freezers for years the other has designed its own case picking application that it intends to put out for bid to the materials handling community Both say they may commercialize their solutions in the future

VERSATILITY MATTERSQuality Wildeck construction and versatility make the V-lifttrade the ultimate lifting solution

In todayrsquos lsquogreenrsquo building designs floor space is at a premium and moving up not out is definitely preferred Look no further than the V-Lifttrade from Wildeck ndash the industry leader in space optimization The single cylinder hydraulic system eliminates all moving hoses cables and chains Fewer components means easy installation reduced maintenance and longer service life To get more value out of your operation contact a Wildeck representative today

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MEZZANINESCapacity Matters Efficiency Matters

LIFT SYSTEMSSafety MattersGUARDING PRODUCTS

able to make better decisionsmdashespecially in the case of the unexpected ldquoWhen a shipment is held up at the portrdquo says Prashant Bhatia director of solutions management at SAP ldquoit can trigger logic back to say that Irsquove got a problem I can no longer allocate that inventory on that particular shipment as I thought I couldrdquo

3 One database one system one supply chain In the last few years soft-ware providers have been pulling all of their products onto a single supply chain process platform ldquoItrsquos fairly newrdquo says Lamphier ldquoVarious components have been integrated into that supply chain process platform longer than others but actually moving our WMS onto it has been a more recent developmentmdashjust within the last quarter or twordquo

SAP uses its enterprise resource planning (ERP) system as the central repository of information of supply and demand as well as inventory for the entire supply chain And the modules all

talk to each other Transportation man-agement systems (TMS) in conjunction with the event management modules help optimize freight determine pick-up windows determine carriers keep track of in-transit times and create ASNs

That ASN not only gets sent back to the ERP for visibility but it also gets sent to the WMS where the sys-tem uses the information to plan labor equipment and resources at the receiv-ing dock When the physical product arrives logic within the WMS based on the receipt of goods determines matches against actual demand

Smarter speedier equipment With more retailers crossdocking

over 50 of their items at the case level to their stores equipment innovations have centered on conveyor sortation systems print and apply mechanisms and automatic identifi cation technolo-gies Here are three new equipment

advances1 Smaller gaps and self-regulat-

ing conveyors In the last year the sliding shoe sorter has undergone note-worthy transformations ldquoBy doing a par-allel divert we can now run the packages closer together and get a higher through-put on the same systemrdquo reports Ken Ruehrdanz manager for Dematicrsquos distri-bution and warehousing markets

The sliding shoes that used to physi-cally push the cartons off the sorter at an angle can now run those shoes in parallel enabling smaller gaps between cartonsmdashwhich were previously from 6 inches to 8 inchesmdashdown to 3 inches

With more dense traffi c on conveyors crossdock operators can run their con-veyors at a lower speed while still achiev-ing the same throughput Slower speeds equal less wear and tear decreased energy usage and less maintenance

Another conveyor breakthrough is automatic speed control ldquoThe whole

m m h c o m MODERN MATERIALS HANDLING A P R I L 2 0 1 0 49S

MMH100401sup_Crossdock_ID 49 482010 113620 AM

Leading customers are investing in software and automated

systems to improve business according to attendees of the

Supply Chain Reset conference

mmh1010_newsindd 12 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 13

THE INDUSTRIAL REAL ESTATEmarket is taking steps in the right direction according to a report recently issued by global real estate fi rm Jones Lang LaSalle (JLL wwwjoneslanglasallecom) which report-ed the national average vacancy rate for the North American industrial real estate sector fell from 106 in the fi rst quarter to 104 in the second quarter Despite the slight decline in vacancy the fragile economy still looms large due to declining con-sumer confi dence the drying up of economic stimulus funding and the potential threat of a double-dip recession the report noted

ldquoWe have seen a positive absorp-tion in the vacancy rate in the second quarter but we are very concerned

going forwardrdquo Craig Meyer managing director and leader of JLLrsquos Logistics and Industrial Services Group told Modern ldquoAny kind of sustained demand-driven component in the industrial real estate market is going to be driven by jobs We are just not seeing any of that It is going to be a long slow recoveryrdquo

Looking at base indicators like the Institute of Supply Managementrsquos Manufacturing Index Consumer Confi dence data and industrial real estate vacancy and absorption rates there does not appear to be what Meyer labeled as a strong indication of a positive upswing on the horizon

The report says that a need to restock inventories that were running at 50-year lows resulted in large com-panies strategically capturing high

quality logistics space at cyclically low rates And with slow levels of leasing activity and sparse construc-tion industrial real estate optionsmdashespecially in the Class A large block sectormdashare limited in some markets

And the swift correction in invento-ries during the second half of 2009 and fi rst quarter of 2010 has left inventory levels lean and ready for expansion provided sales rebound in the coming months Should this occur it could lead to increased industrial and logistics real estate leasing activity

The report also pointed out that the initial recovery in the economy was largely driven by improvements in the manufacturing sector and cyclical adjustments in inventories But with the recovery now becoming more broad-based the recent slowdown of inven-tory building could have more of an impact on the industrial property sector than the offi ce sector the report noted

Date 090910 Client Rehrig Pacifi c Job 08312010 File Name 0831_RPC_SlipSheet_Ad_MMH_Oct10 Round

Account Director Niki Phan Designer Revised By ov Editor Production ov

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Publication(s) TBD Run Date(s) TBD

Approved By

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Available in standard or custom sizes with a variety of surface textures and embossed patterns Rehrig Slip Sheets provide superior slide resistance keeping goods securely in place Manufactured from nearly 100 recycled material each sheet is also 100 recyclable

Beyond the sale Rehrig can help you develop a customized re-use or buy-back program further lowering your average cost per trip

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WAREHOUSESDCS

Industrial real estate market making progress challenges remain

mmh1010_newsindd 13 101310 1049 AM

14 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

ldquoWe are also concerned about seasonality with the holiday season coming uprdquo said Meyer ldquoThe indica-tions we are getting are that we may not see as much preparation for that as we hoped A lot of retailers are saying they are restocked and if consumer confi dence is going down they are not going to build up inventories And for larger big box companies they will see declining values in rents but the availability of product for them to lease is diminishingrdquo

As a result Class A big box dis-tribution space is becoming more diffi cult to fi nd in this economy said Meyer But the build-to-suit market could come back for major retailers as evidenced by a new 1-million-square-foot DC space deal by Amazoncom in Harrisburg Pa and a 14-million-square-foot location in Phoenix

But for a mid-sized industrial building in the 100000-to-150000-square-foot range Class B-sized build-

ing Meyer said there are an infi nite number of these on the market

Looking ahead Meyer said there will still be downward pressure on pric-

ing a double-digit vacancy rate and no increases in lease rates which he noted are actually weakening a little bit and tend to lag a recovery

Power AND CoNtrol

Introducing the latest innovations for incorporating Power AND Control into

your 24 VDC conveyor system

For over 60 years Itoh Denki has been the proven leader in the development and manufacture of superior motorized rollers and components This history provides you confidence in your 24V conveyor applications and designs a confidence based on the component integrity offered by the only sole source motor and control manufacturer in the industry

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LIFTrdquoBFL lifts are designed to move large loads ormultiple pallets betweenfloors These lifts willtravel from 8 feet to 18feet and have platformsizes ranging from 6rsquo x 8rsquo up to 8rsquo x 12rsquoThey are ideal for movinglarge loads 1-2 floors orup to high stages andmezzanines

1-800-843-3625wwwadvancel i f ts com

BFL AD MMH APRIL 92710 358 PM Page 1

CROWN EQUIPMENT Corp has quali-fi ed 20 of its electric models to operate with various fuel cells bringing the total of qualifi ed combinations of fuel cell packs and trucks to 29 In 2009 Crown (wwwcrowncom) was the fi rst lift truck manufacturer to introduce a fuel cell qualifi cation program

Eric Jensen Crownrsquos manager of new technology research and de-velopment told Modern that the companyrsquos fuel cell qualifi cation pro-gram duplicates its own testing and is conducted at a 25000-square-foot research facility near Dayton Ohio Through the testing process engi-

neers evaluate fuel cell performance and monitor whether issues develop that affect the truckrsquos operation

To qualify a fuel cell pack and truck combination Crownrsquos engineers review key performance metrics for a battery-powered truck such as traction plug-ging and lift and travel speeds Then they replace the battery with a fuel cell power pack and measure the same indicators Through modeling and ap-plication testing the research team de-termines design modifi cations needed to ensure the fuel cell-powered forklift matched standards to which the truck was designed

LIFT TRUCKS

Crown unveils 20 electric lift trucks to operate with fuel cells

mmh1010_newsindd 14 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 15

ldquoWersquove been steadfast in our posi-tion that deployment of a fuel cell forklift fl eet must be carefully evalu-ated and tested for appropriate use in a warehouserdquo said Jensen ldquoThis research-based approach means that our customers can confi dently know they have the right truck for their chosen fuel cell allowing them to meet their performance safety and

environmental sus-tainability goalsrdquo

Crown continues to work closely with fuel cell manufactur-ers and customers to qualify trucks as new fuel cell pack models are intro-duced ldquoForklifts are a key early market for fuel cellsrdquo said Lisa Callaghan Jerram senior market analyst for Fuel Cell Today a leading analyst

fi rm providing market-based research on the fuel cell industry ldquoBased on our market research we have found strong growth in this sector in the past three yearsrdquo

Because fuel cell powered electric forklifts give off exhaust in the form of moist warm air IC truck custom-ers are looking to this technology

so they donrsquot have to deal exhaust issues Jensen said Another advan-tage pointed out by Jensen is a fuel cell powered truckrsquos ability to effec-tively operate in a cold environment because they generate their own heat and the power doesnrsquot fall off like a traditional battery

While the upfront hardware cost of fuel cells is more expensive than a traditional battery Jensen pointed out the potential to capture savings in labor battery changes battery rooms and heating and venting With fuel cells he said a facility doesnrsquot need a battery room and all that goes in to running it properly Instead there is an ongoing savings associated to using fl oor space for production or other value-added operations

ldquoFuel cells have always been talked about fi ve years into the future but we have customers who are [currently] planning installations around this prod-uctrdquo said Jensen ldquoThe future is hererdquo

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Call one of our ClearSpan Specialists at 18666431010 or visit us at wwwClearSpancom Mention code CST1109

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Subject to credit approval

To qualify a fuel cell pack and truck combination engineers

review key performance metrics

mmh1010_newsindd 15 101310 1049 AM

lift truck TIPS

GraphicCaption

In the right application tuggers and carts can be a fast and efficient solution

Level the playing field

Football season is under-way and fans are hoping for breakout performances

from stars and rookies alike On the gridiron an overpowered player can be a distinct advan-tage In the warehouse how-ever too much power can lead to waste danger and sluggish performance For some corpo-rations this fact has prompted consideration of fork-free envi-ronments where versatile and custom-built carts and tuggers can do the work faster and more efficiently than their big-ger cousins

Disposing of expensive and powerful equipment in favor of carts may seem counter-intuitive but Jill Burrow marketing manager for Topper Industrial says certain warehouses might benefit greatly from the switch For operations requiring multiple trips between the same areas carts can cut travel time sig-nificantly According to Ed Brown president of Topper Industrial a tugger can pull as many as 13 carts In addi-tion says Brown carts and tuggers can be easier to use than many forklifts

ldquoA forklift costs five times as much but a forklift opera-tor also costs five times more than a tugger operatorrdquo says Brown ldquoAnyone can grab a tugger and gordquo

Once a forklift drops off a pallet in many cases a picker must bend to access product or arrange for the pallet to be lifted Carts on the other hand can be configured with swiveling or angled platforms to allow pickers fast and comfortable access to products Worker safety issues tied to forklifts that operate in tight areas such as poor visibility when driving in re-verse and dock mishaps can also be greatly reduced

ldquoCompanies looking at carts are looking at the cost of equipment and the cost of maintenance but theyrsquore also looking at safetyrdquo says Brown

In addition to ergonomics and safety a fork-free zone might help a warehouse reduce product loss and equip-ment damage Carts provide a secure cradle for moving product while some fork-borne loads are prone to top-pling And forklifts often 10 times as heavy as a tugger and cart setup have a way of proving their strength by leaving dings and dents on storage racks and other hap-less stationary objects

With carts and tuggers Brown says most companies see a return on investment within a year In football a first-round draft pick can cost millions over a multi-year contract before he produces the desired results For com-panies not looking to attempt such a Hail Mary tuggers could prove an efficient alternative

Josh Bond is a contributing editor to Modern and can be reached at turbobondgmailcom

16 O c t O b e r 2 0 1 0 Modern Materials Handling m m h c o m

lift truck TIPS

By Josh Bond Contributing Editor

MMH1010_LiftTruckTipsindd 16 101310 942 AM

MM100601Adsindd 3 6310 349 PMMMH1010_Adsindd 17 101210 1053 AM

18 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

Keith arntson vice president of distribution operations for

del Monte Foods

Four conveyor-topped vehicles ferry loads from an adjacent manufacturing plant

MMH1010_SystemRptDelMonteindd 18 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

bull Discover the newest robotics products and services bull See the latest robot-based solutions for picking and palletizing bull Understand how intelligent robots are revolutionizing processing

packaging plant operations and material handling bull Learn about robotics solutions that will increase your bottom line

Sponsoring companies include

Register TodaymdashItrsquos FREE Go to robovirtualeventscom

ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

Denso RoboticsElite EngineeringFANUC RoboticsFood EngineeringGenesis Systems GroupHartness InternationalKIva Systems

Modern Materials HandlingMotion Control RoboticsNational InstrumentsOmron Scientifi c Technologies IncRobotics TrendsWind RiverYaskawa Motoman Robotics

MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 9: Modern Materials Handling - October 2010

Modern Materials Logistics Management Supply Chain Management

bull Automation

bull Conveyors amp Sorters

bull Inventory amp Picking

bull Loading Dock Equipment

bull Mobile amp Wireless

bull Shipping Pallets

bull Storage Systems

bull Containers amp Totes

bull Energy amp Sustainability

bull Lift Truck amp Fork Lift

bull Handling amp Warehouse Ergonomics

bull Packaging

bull Software amp Technology

wwwmmhcomcriticaltopics

Critical Industry News at Your Fingertips

Critical Topic areas help you develop strategies and expand your knowledge Each topic provides you with the news information and resources you need mdash each day

CRITICAL TOPICS

Modern Materials Logistics Management Supply Chain Management

MMH_CriticalTopics_Houseindd 1 81010 117 PMMMH1010_Adsindd 8 101210 1053 AM

ITrsquoS STILL A FAR CRY FROM 2007 but the materials handling industry is growing once again Following a 343 decline in equipment orders in 2009 the Material Handling Industry of America (MHIA wwwmhiaorg) is forecasting equipment orders to grow 12 to 14 in 2010 if the current momentum continues

A variety of factors are driving growth in manufacturing warehous-ing and distribution on a global basis especially an increase in industrial pro-duction in the fi rst half of 2010 despite factory utilization rates that remain very low by historical comparison

ldquoConsumer demand has not returnedrdquo Hal Vandiver executive vice president of business develop-ment for MHIA told Modern during the associationrsquos fall meeting ldquoBut in the fi rst two quarters the economy shifted from recession into recovery mode fi lling supply chain pipelines re-establishing inventories and re-sponding to pent up demandrdquo

While Vandiver expects the indus-try to continue to grow by 11 to 12 in 2011 drags on the economy continue ldquoForecasts are now calling for a combination of reduced GDP corporate profi t business investment and output growth with industrial utilization remaining below 75 until

late 2011rdquo Vandiver said ldquoThis is largely due to uncertainty Consumers inves-tors and business owners need greater confi dence in the economyrsquos ability to sustain positive growthrdquo For those reasons Vandiver doesnrsquot expect a signifi cant return to the kinds of num-bers the industry posted in the past up until 2007

In addition to

a growth in orders for new equipment Van-diver forecasts material handling shipments to grow 3 to 4 in 2010 and another 10 to 11 in 2011 Domestic demand defi ned as shipments plus imports less exports will grow by 1 in 2010 and by 10 to 11 in 2011 Exports will be stronger than im-ports in 2010 and 2011 refl ecting stronger indus-trial growth in emerging markets outside North America

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 9

Company Briefi ngs | Bob Trebilcock

The age of automationExpressed as an equation The industrial age + the information age = the automation age

mmhcomblogsautomation

Diblogbest of Modernrsquos blogs

BY BOB TREBILCOCK EXECUTIVE EDITOR

ECONOMY

MHIA Growth is backMHIA FORECASTS 12 TO 14 GROWTH IN NEW EQUIPMENT ORDERS IN 2010

0

-343

2009 2010

130(forecast)

MHIA equipment orders forecast

Source Material Handling Industry of America (MHIA)

HIGHJUMP SOFTWARE announced today that it has reached agreement to acquire TrueCommerce a provider of business-to-business integration solutions TrueCommerce provides a comprehensive end-to-end suite of trading partner connectivity solutions including electronic data interchange (EDI) translation and data mapping software transaction network and on-boarding services HighJump Software (wwwhighjumpcom) ranks

No 11 on Modernrsquos 2010 Supply Chain Management Software an-nual list with $85 million in revenue TrueCommercersquos solutions enable trading partner connectivity for 3000 customers feature predefi ned inte-gration to many major ERP systems and can be deployed in either SaaS or on-premise models

The TrueCommerce trading part-ner integration solution complements HighJump Softwarersquos existing supply

MampA

HighJump to acquire TrueCommerce

mmh1010_newsindd 9 101310 1049 AM

middot Robotic palletizing cells handle goods at the end of the production linemiddot LGVs transport pallets to stretch wrapping and labelingmiddot LGVs transport finished pallets to the warehousemiddot LGVs for Storage amp Retrieval (SRS)middot LGVs for Auto-Trailer Loading (ATL)middot An integrated software management system

Elettric 80 is a global provider of end-of-lineautomation solutions These solutions are called Freewayreg material handling system

The technologies are adaptable and have a high degree of built-in flexibility which makes them suitable for any plant warehouse layout or design More details explanatory videos and animations can be found at wwwelettric80com

ITALY middot USA middot SWEDEN middot UK middot AUSTRALIA middot POLAND

Elettric 80 Inc8100 Monticello AvenueSkokie IL 60076 USAPhone +1 847 329 7717e80usaelettric80it

Freewayreg is based on a simple idea

C

M

Y

CM

MY

CY

CMY

K

el80_US_verticalpdf 1 2010-09-29 1346

chain application suite which spans from supplier to store shelf and includes warehouse management systems transportation management systems route accounting systems manufacturing execution mobile sales and ERP data collection Trading partner collaboration is increas-ingly important as organizations strive to reduce costs and improve service levels By combining integration solutions with application functionality organizations are able to ensure consistency in business processes and accuracy of information exchanged with trading partners

ldquoTrueCommerce has fi lled a unique need in the market for simple robust and affordable EDI solutions for small and midsized businessesrdquo said Nick Manolis TrueCom-merce CEO ldquoI am excited for the TrueCommerce team to join HighJump while continuing to provide excellent service support and product innovation to our customersrdquo

ldquoCombining HighJump and TrueCommerce creates a unique and compelling solution offering within the supply chain software marketrdquo said Russell Fleischer HighJump Software CEO ldquoOur view is that supply chain applications must allow users to connect with a broad ecosystem of trading partners to maximize value The TrueCommerce solution platform and our previous move to cloud-based applications will help translate this vision into reality for our customersrdquo

SUPPLY CHAIN NEWS ANALYSIS

Final thoughts on Supply Chain Reset conferenceBY BOB TREBILCOCK EXECUTIVE EDITOR

DESPITE SIGNS OF IMPROVEMENTS doing business in in materials handling remains a challenge At the same time many of the leading customers are investing in supply chain software and automated materials handling systems to improve their businesses That suggests better times are coming

Tom Brokaw punctuates the 25th anniversary of the Material

Handling and Logistics Conference by HK Systems

mmh1010_newsindd 10 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 11

Leader of the PackThe originator of high speed narrow belt sortationTGW Systems has led the way in offering provenadvantages over conventional sortation for over 10 years

NBS fromTGW Systems

50 less install time60 less energy75 less noise

100 of the Value

wwwtgw-groupcom

TGW Systems (formerly TGW-Ermanco) is an integrated logistics solutions and material handling equipment provider The Ermanco name lives onas the product family name for the conveying andsortation products manufactured in the US

Our worldwide perspective and resources and commitment to innovation product developmentand unparalleled customer service can help you today

Proven track record ndash Over 700 installations around the world have made TGWrsquos Narrow Belt Sorter one of the most reliable sorters available

Rugged durability ndash TGWrsquos NBS sorters operate in some of the harshest distribution environments in the world earning customerrsquos admiration and competitorrsquos respect

Application and layout fl exibility ndash The universal frame on TGWrsquos narrow belt sorter means you can use multiple divert options and easily add divert modules after installation for increased fl exibility

Patented technology ndash Patented sortation technology in the TGWrsquos narrow belt sorter continues to lead the way in effective energy effi cient fl exible sortation

10 08 NBSindd 1 8302010 34008 PM

keep enough labor to run his primary distribution center Two presentations drove this point home The fi rst was from an executive with Tim Hor-tons the Dunkin Donuts of Canada The companyrsquos beautiful new DC in Guelph Ontario is underperforming projections even though the ASRS is

living up to its promises The reason The company canrsquot fi nd enough labor willing to work in its case picking and palletizing operations The other was by Terra Winston a consultant who presented a case study about a proj-ect at PepsiCo to develop the next wave of supply chain leaders Her

Those are the two high level take-aways from Supply Chain Reset the annual logistics conference held last month in Park City Utah sponsored by HK Systems now part of Dematic

ldquoLousyrdquo was the most common response to the dinner-time question ldquoHowrsquos businessrdquo

At the same time the roll call of end user companies that said they had projects in the works or on the drawing board was both a Whorsquos Who of American business with names like Coca-Cola and Kraft and companies many of us may never have heard of or think of as custom-ers of our solutions For example I sat on the van from the airport with a guy from the Los Angeles metro-politan transportation system looking for a new automated storage and retrieval system (ASRS) The Federal Reserve Bank was there investigat-ing storage systems I rode in the van back to the airport with a woman from a producer of honey in Texas who had both an ASRS and auto-matic guided vehicles in her facil-ity and was looking to expand her system

Those are signs of a growing con-fi dence I donrsquot think companies plan multi-million dollar investments in au-tomation if they think the apocalypse is right around the corner

One other anecdotal data point Marc Ducharme a vice president and partner with Axium a supplier of robotic materials handling solu-tions told me that 2009 was a dismal year for implementations but that his company has been swamped with RFPs in 2010 An RFP is not an order but itrsquos a sign

A few other observationsRetaining labor and talent could

be the most important issue facing the industry in the future A week or so before going to Utah I had a con-versation with a vice president of sup-ply chain for a major retailer who told me he is interested in automation because he simply cannot fi nd and

mmh1010_newsindd 11 101310 1049 AM

12 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

point the talent shortage isnrsquot limited just to the shop fl oor

Retrofi tting is a viable solution You know the old saying Every-thing old is new again Wegmanrsquos a Midwestern grocer and Rubber-maid both gave strong presenta-tions about how they replaced ag-ing ASRS cranes to breathe new life into their DCs Meanwhile Anheuser Busch gained new ef-fi ciencies in its Columbus Ohio facility by upgrading a warehouse control system

Everyone loves pallets Based in Iowa Green Line Armor is offering a heavy-duty hybrid woodplastic pallet for permanent pallet pools The 48- x 40-inch pallet has heavier stringers and more deck board coverage than a grocery pallet The lead boards on the top and the bottom of the palletmdashthose most likely to get damaged by a lift truckmdashare manufactured from heavy plastic The pallet has a passive RFID

tag that is used by Green Line Armor to identify the pallet and manage war-ranty services Active RFID tags were installed for John Deere the companyrsquos largest customer to track the location of work in process stored on the pallets between manufacturing processes Eric Renteria the companyrsquos president said the pallets which come with a 10-year warranty can be purchased or leased

in a pooling modelNew players are get-

ting into automation Kip Tygard whose company makes the Tygard Claw a lift truck attachment for mixed case palletizing is investing RampD money to develop an automated version of the Claw Thatrsquos not a big shock Tygard is an OEM But I also had conversations with two very large end users in the wholesale food distribu-

tion business that have designed their own automated systemsmdashone has built and implemented its own ASRS design for freezers for years the other has designed its own case picking application that it intends to put out for bid to the materials handling community Both say they may commercialize their solutions in the future

VERSATILITY MATTERSQuality Wildeck construction and versatility make the V-lifttrade the ultimate lifting solution

In todayrsquos lsquogreenrsquo building designs floor space is at a premium and moving up not out is definitely preferred Look no further than the V-Lifttrade from Wildeck ndash the industry leader in space optimization The single cylinder hydraulic system eliminates all moving hoses cables and chains Fewer components means easy installation reduced maintenance and longer service life To get more value out of your operation contact a Wildeck representative today

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800-325-6939 | WWWWILDECKCOM

MEZZANINESCapacity Matters Efficiency Matters

LIFT SYSTEMSSafety MattersGUARDING PRODUCTS

able to make better decisionsmdashespecially in the case of the unexpected ldquoWhen a shipment is held up at the portrdquo says Prashant Bhatia director of solutions management at SAP ldquoit can trigger logic back to say that Irsquove got a problem I can no longer allocate that inventory on that particular shipment as I thought I couldrdquo

3 One database one system one supply chain In the last few years soft-ware providers have been pulling all of their products onto a single supply chain process platform ldquoItrsquos fairly newrdquo says Lamphier ldquoVarious components have been integrated into that supply chain process platform longer than others but actually moving our WMS onto it has been a more recent developmentmdashjust within the last quarter or twordquo

SAP uses its enterprise resource planning (ERP) system as the central repository of information of supply and demand as well as inventory for the entire supply chain And the modules all

talk to each other Transportation man-agement systems (TMS) in conjunction with the event management modules help optimize freight determine pick-up windows determine carriers keep track of in-transit times and create ASNs

That ASN not only gets sent back to the ERP for visibility but it also gets sent to the WMS where the sys-tem uses the information to plan labor equipment and resources at the receiv-ing dock When the physical product arrives logic within the WMS based on the receipt of goods determines matches against actual demand

Smarter speedier equipment With more retailers crossdocking

over 50 of their items at the case level to their stores equipment innovations have centered on conveyor sortation systems print and apply mechanisms and automatic identifi cation technolo-gies Here are three new equipment

advances1 Smaller gaps and self-regulat-

ing conveyors In the last year the sliding shoe sorter has undergone note-worthy transformations ldquoBy doing a par-allel divert we can now run the packages closer together and get a higher through-put on the same systemrdquo reports Ken Ruehrdanz manager for Dematicrsquos distri-bution and warehousing markets

The sliding shoes that used to physi-cally push the cartons off the sorter at an angle can now run those shoes in parallel enabling smaller gaps between cartonsmdashwhich were previously from 6 inches to 8 inchesmdashdown to 3 inches

With more dense traffi c on conveyors crossdock operators can run their con-veyors at a lower speed while still achiev-ing the same throughput Slower speeds equal less wear and tear decreased energy usage and less maintenance

Another conveyor breakthrough is automatic speed control ldquoThe whole

m m h c o m MODERN MATERIALS HANDLING A P R I L 2 0 1 0 49S

MMH100401sup_Crossdock_ID 49 482010 113620 AM

Leading customers are investing in software and automated

systems to improve business according to attendees of the

Supply Chain Reset conference

mmh1010_newsindd 12 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 13

THE INDUSTRIAL REAL ESTATEmarket is taking steps in the right direction according to a report recently issued by global real estate fi rm Jones Lang LaSalle (JLL wwwjoneslanglasallecom) which report-ed the national average vacancy rate for the North American industrial real estate sector fell from 106 in the fi rst quarter to 104 in the second quarter Despite the slight decline in vacancy the fragile economy still looms large due to declining con-sumer confi dence the drying up of economic stimulus funding and the potential threat of a double-dip recession the report noted

ldquoWe have seen a positive absorp-tion in the vacancy rate in the second quarter but we are very concerned

going forwardrdquo Craig Meyer managing director and leader of JLLrsquos Logistics and Industrial Services Group told Modern ldquoAny kind of sustained demand-driven component in the industrial real estate market is going to be driven by jobs We are just not seeing any of that It is going to be a long slow recoveryrdquo

Looking at base indicators like the Institute of Supply Managementrsquos Manufacturing Index Consumer Confi dence data and industrial real estate vacancy and absorption rates there does not appear to be what Meyer labeled as a strong indication of a positive upswing on the horizon

The report says that a need to restock inventories that were running at 50-year lows resulted in large com-panies strategically capturing high

quality logistics space at cyclically low rates And with slow levels of leasing activity and sparse construc-tion industrial real estate optionsmdashespecially in the Class A large block sectormdashare limited in some markets

And the swift correction in invento-ries during the second half of 2009 and fi rst quarter of 2010 has left inventory levels lean and ready for expansion provided sales rebound in the coming months Should this occur it could lead to increased industrial and logistics real estate leasing activity

The report also pointed out that the initial recovery in the economy was largely driven by improvements in the manufacturing sector and cyclical adjustments in inventories But with the recovery now becoming more broad-based the recent slowdown of inven-tory building could have more of an impact on the industrial property sector than the offi ce sector the report noted

Date 090910 Client Rehrig Pacifi c Job 08312010 File Name 0831_RPC_SlipSheet_Ad_MMH_Oct10 Round

Account Director Niki Phan Designer Revised By ov Editor Production ov

Color 4CProcess Trim 7 times 4625 Bleed 0 Safety 675times 4375 Fold na

Publication(s) TBD Run Date(s) TBD

Approved By

A FAMILY TRADITION OF GROWTH SERVICE AND INNOVATION

Give Your Heavy Pallets the Slip

Material Handling

Ship more product per load with Rehrigrsquos weight space and cost saving Slip Sheets

Rehrig co-extruded Slip Sheets are a cost-effective alternative to pallets Impervious to moisture high tensile strength plastic provides added tear resistance making them the perfect replacement for fi ber or corrugated sheets as well

Available in standard or custom sizes with a variety of surface textures and embossed patterns Rehrig Slip Sheets provide superior slide resistance keeping goods securely in place Manufactured from nearly 100 recycled material each sheet is also 100 recyclable

Beyond the sale Rehrig can help you develop a customized re-use or buy-back program further lowering your average cost per trip

Phone (800) 546-4993 Email inforehrigpacificcom Web wwwrehrigpacificcom

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Come see us at Pack ExpoBooth S-5000

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WAREHOUSESDCS

Industrial real estate market making progress challenges remain

mmh1010_newsindd 13 101310 1049 AM

14 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

ldquoWe are also concerned about seasonality with the holiday season coming uprdquo said Meyer ldquoThe indica-tions we are getting are that we may not see as much preparation for that as we hoped A lot of retailers are saying they are restocked and if consumer confi dence is going down they are not going to build up inventories And for larger big box companies they will see declining values in rents but the availability of product for them to lease is diminishingrdquo

As a result Class A big box dis-tribution space is becoming more diffi cult to fi nd in this economy said Meyer But the build-to-suit market could come back for major retailers as evidenced by a new 1-million-square-foot DC space deal by Amazoncom in Harrisburg Pa and a 14-million-square-foot location in Phoenix

But for a mid-sized industrial building in the 100000-to-150000-square-foot range Class B-sized build-

ing Meyer said there are an infi nite number of these on the market

Looking ahead Meyer said there will still be downward pressure on pric-

ing a double-digit vacancy rate and no increases in lease rates which he noted are actually weakening a little bit and tend to lag a recovery

Power AND CoNtrol

Introducing the latest innovations for incorporating Power AND Control into

your 24 VDC conveyor system

For over 60 years Itoh Denki has been the proven leader in the development and manufacture of superior motorized rollers and components This history provides you confidence in your 24V conveyor applications and designs a confidence based on the component integrity offered by the only sole source motor and control manufacturer in the industry

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Intelligent solutions yoursquod expect from Itoh Denki Intelligent solutions yoursquod expect from Itoh Denki

BFL SERIESldquoBIG FRIGGIN

LIFTrdquoBFL lifts are designed to move large loads ormultiple pallets betweenfloors These lifts willtravel from 8 feet to 18feet and have platformsizes ranging from 6rsquo x 8rsquo up to 8rsquo x 12rsquoThey are ideal for movinglarge loads 1-2 floors orup to high stages andmezzanines

1-800-843-3625wwwadvancel i f ts com

BFL AD MMH APRIL 92710 358 PM Page 1

CROWN EQUIPMENT Corp has quali-fi ed 20 of its electric models to operate with various fuel cells bringing the total of qualifi ed combinations of fuel cell packs and trucks to 29 In 2009 Crown (wwwcrowncom) was the fi rst lift truck manufacturer to introduce a fuel cell qualifi cation program

Eric Jensen Crownrsquos manager of new technology research and de-velopment told Modern that the companyrsquos fuel cell qualifi cation pro-gram duplicates its own testing and is conducted at a 25000-square-foot research facility near Dayton Ohio Through the testing process engi-

neers evaluate fuel cell performance and monitor whether issues develop that affect the truckrsquos operation

To qualify a fuel cell pack and truck combination Crownrsquos engineers review key performance metrics for a battery-powered truck such as traction plug-ging and lift and travel speeds Then they replace the battery with a fuel cell power pack and measure the same indicators Through modeling and ap-plication testing the research team de-termines design modifi cations needed to ensure the fuel cell-powered forklift matched standards to which the truck was designed

LIFT TRUCKS

Crown unveils 20 electric lift trucks to operate with fuel cells

mmh1010_newsindd 14 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 15

ldquoWersquove been steadfast in our posi-tion that deployment of a fuel cell forklift fl eet must be carefully evalu-ated and tested for appropriate use in a warehouserdquo said Jensen ldquoThis research-based approach means that our customers can confi dently know they have the right truck for their chosen fuel cell allowing them to meet their performance safety and

environmental sus-tainability goalsrdquo

Crown continues to work closely with fuel cell manufactur-ers and customers to qualify trucks as new fuel cell pack models are intro-duced ldquoForklifts are a key early market for fuel cellsrdquo said Lisa Callaghan Jerram senior market analyst for Fuel Cell Today a leading analyst

fi rm providing market-based research on the fuel cell industry ldquoBased on our market research we have found strong growth in this sector in the past three yearsrdquo

Because fuel cell powered electric forklifts give off exhaust in the form of moist warm air IC truck custom-ers are looking to this technology

so they donrsquot have to deal exhaust issues Jensen said Another advan-tage pointed out by Jensen is a fuel cell powered truckrsquos ability to effec-tively operate in a cold environment because they generate their own heat and the power doesnrsquot fall off like a traditional battery

While the upfront hardware cost of fuel cells is more expensive than a traditional battery Jensen pointed out the potential to capture savings in labor battery changes battery rooms and heating and venting With fuel cells he said a facility doesnrsquot need a battery room and all that goes in to running it properly Instead there is an ongoing savings associated to using fl oor space for production or other value-added operations

ldquoFuel cells have always been talked about fi ve years into the future but we have customers who are [currently] planning installations around this prod-uctrdquo said Jensen ldquoThe future is hererdquo

Buildings available up to

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property taxes

Call one of our ClearSpan Specialists at 18666431010 or visit us at wwwClearSpancom Mention code CST1109

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Subject to credit approval

To qualify a fuel cell pack and truck combination engineers

review key performance metrics

mmh1010_newsindd 15 101310 1049 AM

lift truck TIPS

GraphicCaption

In the right application tuggers and carts can be a fast and efficient solution

Level the playing field

Football season is under-way and fans are hoping for breakout performances

from stars and rookies alike On the gridiron an overpowered player can be a distinct advan-tage In the warehouse how-ever too much power can lead to waste danger and sluggish performance For some corpo-rations this fact has prompted consideration of fork-free envi-ronments where versatile and custom-built carts and tuggers can do the work faster and more efficiently than their big-ger cousins

Disposing of expensive and powerful equipment in favor of carts may seem counter-intuitive but Jill Burrow marketing manager for Topper Industrial says certain warehouses might benefit greatly from the switch For operations requiring multiple trips between the same areas carts can cut travel time sig-nificantly According to Ed Brown president of Topper Industrial a tugger can pull as many as 13 carts In addi-tion says Brown carts and tuggers can be easier to use than many forklifts

ldquoA forklift costs five times as much but a forklift opera-tor also costs five times more than a tugger operatorrdquo says Brown ldquoAnyone can grab a tugger and gordquo

Once a forklift drops off a pallet in many cases a picker must bend to access product or arrange for the pallet to be lifted Carts on the other hand can be configured with swiveling or angled platforms to allow pickers fast and comfortable access to products Worker safety issues tied to forklifts that operate in tight areas such as poor visibility when driving in re-verse and dock mishaps can also be greatly reduced

ldquoCompanies looking at carts are looking at the cost of equipment and the cost of maintenance but theyrsquore also looking at safetyrdquo says Brown

In addition to ergonomics and safety a fork-free zone might help a warehouse reduce product loss and equip-ment damage Carts provide a secure cradle for moving product while some fork-borne loads are prone to top-pling And forklifts often 10 times as heavy as a tugger and cart setup have a way of proving their strength by leaving dings and dents on storage racks and other hap-less stationary objects

With carts and tuggers Brown says most companies see a return on investment within a year In football a first-round draft pick can cost millions over a multi-year contract before he produces the desired results For com-panies not looking to attempt such a Hail Mary tuggers could prove an efficient alternative

Josh Bond is a contributing editor to Modern and can be reached at turbobondgmailcom

16 O c t O b e r 2 0 1 0 Modern Materials Handling m m h c o m

lift truck TIPS

By Josh Bond Contributing Editor

MMH1010_LiftTruckTipsindd 16 101310 942 AM

MM100601Adsindd 3 6310 349 PMMMH1010_Adsindd 17 101210 1053 AM

18 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

Keith arntson vice president of distribution operations for

del Monte Foods

Four conveyor-topped vehicles ferry loads from an adjacent manufacturing plant

MMH1010_SystemRptDelMonteindd 18 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

bull Discover the newest robotics products and services bull See the latest robot-based solutions for picking and palletizing bull Understand how intelligent robots are revolutionizing processing

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ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

Denso RoboticsElite EngineeringFANUC RoboticsFood EngineeringGenesis Systems GroupHartness InternationalKIva Systems

Modern Materials HandlingMotion Control RoboticsNational InstrumentsOmron Scientifi c Technologies IncRobotics TrendsWind RiverYaskawa Motoman Robotics

MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

chepcomsimplechoice

Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 10: Modern Materials Handling - October 2010

ITrsquoS STILL A FAR CRY FROM 2007 but the materials handling industry is growing once again Following a 343 decline in equipment orders in 2009 the Material Handling Industry of America (MHIA wwwmhiaorg) is forecasting equipment orders to grow 12 to 14 in 2010 if the current momentum continues

A variety of factors are driving growth in manufacturing warehous-ing and distribution on a global basis especially an increase in industrial pro-duction in the fi rst half of 2010 despite factory utilization rates that remain very low by historical comparison

ldquoConsumer demand has not returnedrdquo Hal Vandiver executive vice president of business develop-ment for MHIA told Modern during the associationrsquos fall meeting ldquoBut in the fi rst two quarters the economy shifted from recession into recovery mode fi lling supply chain pipelines re-establishing inventories and re-sponding to pent up demandrdquo

While Vandiver expects the indus-try to continue to grow by 11 to 12 in 2011 drags on the economy continue ldquoForecasts are now calling for a combination of reduced GDP corporate profi t business investment and output growth with industrial utilization remaining below 75 until

late 2011rdquo Vandiver said ldquoThis is largely due to uncertainty Consumers inves-tors and business owners need greater confi dence in the economyrsquos ability to sustain positive growthrdquo For those reasons Vandiver doesnrsquot expect a signifi cant return to the kinds of num-bers the industry posted in the past up until 2007

In addition to

a growth in orders for new equipment Van-diver forecasts material handling shipments to grow 3 to 4 in 2010 and another 10 to 11 in 2011 Domestic demand defi ned as shipments plus imports less exports will grow by 1 in 2010 and by 10 to 11 in 2011 Exports will be stronger than im-ports in 2010 and 2011 refl ecting stronger indus-trial growth in emerging markets outside North America

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 9

Company Briefi ngs | Bob Trebilcock

The age of automationExpressed as an equation The industrial age + the information age = the automation age

mmhcomblogsautomation

Diblogbest of Modernrsquos blogs

BY BOB TREBILCOCK EXECUTIVE EDITOR

ECONOMY

MHIA Growth is backMHIA FORECASTS 12 TO 14 GROWTH IN NEW EQUIPMENT ORDERS IN 2010

0

-343

2009 2010

130(forecast)

MHIA equipment orders forecast

Source Material Handling Industry of America (MHIA)

HIGHJUMP SOFTWARE announced today that it has reached agreement to acquire TrueCommerce a provider of business-to-business integration solutions TrueCommerce provides a comprehensive end-to-end suite of trading partner connectivity solutions including electronic data interchange (EDI) translation and data mapping software transaction network and on-boarding services HighJump Software (wwwhighjumpcom) ranks

No 11 on Modernrsquos 2010 Supply Chain Management Software an-nual list with $85 million in revenue TrueCommercersquos solutions enable trading partner connectivity for 3000 customers feature predefi ned inte-gration to many major ERP systems and can be deployed in either SaaS or on-premise models

The TrueCommerce trading part-ner integration solution complements HighJump Softwarersquos existing supply

MampA

HighJump to acquire TrueCommerce

mmh1010_newsindd 9 101310 1049 AM

middot Robotic palletizing cells handle goods at the end of the production linemiddot LGVs transport pallets to stretch wrapping and labelingmiddot LGVs transport finished pallets to the warehousemiddot LGVs for Storage amp Retrieval (SRS)middot LGVs for Auto-Trailer Loading (ATL)middot An integrated software management system

Elettric 80 is a global provider of end-of-lineautomation solutions These solutions are called Freewayreg material handling system

The technologies are adaptable and have a high degree of built-in flexibility which makes them suitable for any plant warehouse layout or design More details explanatory videos and animations can be found at wwwelettric80com

ITALY middot USA middot SWEDEN middot UK middot AUSTRALIA middot POLAND

Elettric 80 Inc8100 Monticello AvenueSkokie IL 60076 USAPhone +1 847 329 7717e80usaelettric80it

Freewayreg is based on a simple idea

C

M

Y

CM

MY

CY

CMY

K

el80_US_verticalpdf 1 2010-09-29 1346

chain application suite which spans from supplier to store shelf and includes warehouse management systems transportation management systems route accounting systems manufacturing execution mobile sales and ERP data collection Trading partner collaboration is increas-ingly important as organizations strive to reduce costs and improve service levels By combining integration solutions with application functionality organizations are able to ensure consistency in business processes and accuracy of information exchanged with trading partners

ldquoTrueCommerce has fi lled a unique need in the market for simple robust and affordable EDI solutions for small and midsized businessesrdquo said Nick Manolis TrueCom-merce CEO ldquoI am excited for the TrueCommerce team to join HighJump while continuing to provide excellent service support and product innovation to our customersrdquo

ldquoCombining HighJump and TrueCommerce creates a unique and compelling solution offering within the supply chain software marketrdquo said Russell Fleischer HighJump Software CEO ldquoOur view is that supply chain applications must allow users to connect with a broad ecosystem of trading partners to maximize value The TrueCommerce solution platform and our previous move to cloud-based applications will help translate this vision into reality for our customersrdquo

SUPPLY CHAIN NEWS ANALYSIS

Final thoughts on Supply Chain Reset conferenceBY BOB TREBILCOCK EXECUTIVE EDITOR

DESPITE SIGNS OF IMPROVEMENTS doing business in in materials handling remains a challenge At the same time many of the leading customers are investing in supply chain software and automated materials handling systems to improve their businesses That suggests better times are coming

Tom Brokaw punctuates the 25th anniversary of the Material

Handling and Logistics Conference by HK Systems

mmh1010_newsindd 10 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 11

Leader of the PackThe originator of high speed narrow belt sortationTGW Systems has led the way in offering provenadvantages over conventional sortation for over 10 years

NBS fromTGW Systems

50 less install time60 less energy75 less noise

100 of the Value

wwwtgw-groupcom

TGW Systems (formerly TGW-Ermanco) is an integrated logistics solutions and material handling equipment provider The Ermanco name lives onas the product family name for the conveying andsortation products manufactured in the US

Our worldwide perspective and resources and commitment to innovation product developmentand unparalleled customer service can help you today

Proven track record ndash Over 700 installations around the world have made TGWrsquos Narrow Belt Sorter one of the most reliable sorters available

Rugged durability ndash TGWrsquos NBS sorters operate in some of the harshest distribution environments in the world earning customerrsquos admiration and competitorrsquos respect

Application and layout fl exibility ndash The universal frame on TGWrsquos narrow belt sorter means you can use multiple divert options and easily add divert modules after installation for increased fl exibility

Patented technology ndash Patented sortation technology in the TGWrsquos narrow belt sorter continues to lead the way in effective energy effi cient fl exible sortation

10 08 NBSindd 1 8302010 34008 PM

keep enough labor to run his primary distribution center Two presentations drove this point home The fi rst was from an executive with Tim Hor-tons the Dunkin Donuts of Canada The companyrsquos beautiful new DC in Guelph Ontario is underperforming projections even though the ASRS is

living up to its promises The reason The company canrsquot fi nd enough labor willing to work in its case picking and palletizing operations The other was by Terra Winston a consultant who presented a case study about a proj-ect at PepsiCo to develop the next wave of supply chain leaders Her

Those are the two high level take-aways from Supply Chain Reset the annual logistics conference held last month in Park City Utah sponsored by HK Systems now part of Dematic

ldquoLousyrdquo was the most common response to the dinner-time question ldquoHowrsquos businessrdquo

At the same time the roll call of end user companies that said they had projects in the works or on the drawing board was both a Whorsquos Who of American business with names like Coca-Cola and Kraft and companies many of us may never have heard of or think of as custom-ers of our solutions For example I sat on the van from the airport with a guy from the Los Angeles metro-politan transportation system looking for a new automated storage and retrieval system (ASRS) The Federal Reserve Bank was there investigat-ing storage systems I rode in the van back to the airport with a woman from a producer of honey in Texas who had both an ASRS and auto-matic guided vehicles in her facil-ity and was looking to expand her system

Those are signs of a growing con-fi dence I donrsquot think companies plan multi-million dollar investments in au-tomation if they think the apocalypse is right around the corner

One other anecdotal data point Marc Ducharme a vice president and partner with Axium a supplier of robotic materials handling solu-tions told me that 2009 was a dismal year for implementations but that his company has been swamped with RFPs in 2010 An RFP is not an order but itrsquos a sign

A few other observationsRetaining labor and talent could

be the most important issue facing the industry in the future A week or so before going to Utah I had a con-versation with a vice president of sup-ply chain for a major retailer who told me he is interested in automation because he simply cannot fi nd and

mmh1010_newsindd 11 101310 1049 AM

12 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

point the talent shortage isnrsquot limited just to the shop fl oor

Retrofi tting is a viable solution You know the old saying Every-thing old is new again Wegmanrsquos a Midwestern grocer and Rubber-maid both gave strong presenta-tions about how they replaced ag-ing ASRS cranes to breathe new life into their DCs Meanwhile Anheuser Busch gained new ef-fi ciencies in its Columbus Ohio facility by upgrading a warehouse control system

Everyone loves pallets Based in Iowa Green Line Armor is offering a heavy-duty hybrid woodplastic pallet for permanent pallet pools The 48- x 40-inch pallet has heavier stringers and more deck board coverage than a grocery pallet The lead boards on the top and the bottom of the palletmdashthose most likely to get damaged by a lift truckmdashare manufactured from heavy plastic The pallet has a passive RFID

tag that is used by Green Line Armor to identify the pallet and manage war-ranty services Active RFID tags were installed for John Deere the companyrsquos largest customer to track the location of work in process stored on the pallets between manufacturing processes Eric Renteria the companyrsquos president said the pallets which come with a 10-year warranty can be purchased or leased

in a pooling modelNew players are get-

ting into automation Kip Tygard whose company makes the Tygard Claw a lift truck attachment for mixed case palletizing is investing RampD money to develop an automated version of the Claw Thatrsquos not a big shock Tygard is an OEM But I also had conversations with two very large end users in the wholesale food distribu-

tion business that have designed their own automated systemsmdashone has built and implemented its own ASRS design for freezers for years the other has designed its own case picking application that it intends to put out for bid to the materials handling community Both say they may commercialize their solutions in the future

VERSATILITY MATTERSQuality Wildeck construction and versatility make the V-lifttrade the ultimate lifting solution

In todayrsquos lsquogreenrsquo building designs floor space is at a premium and moving up not out is definitely preferred Look no further than the V-Lifttrade from Wildeck ndash the industry leader in space optimization The single cylinder hydraulic system eliminates all moving hoses cables and chains Fewer components means easy installation reduced maintenance and longer service life To get more value out of your operation contact a Wildeck representative today

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MEZZANINESCapacity Matters Efficiency Matters

LIFT SYSTEMSSafety MattersGUARDING PRODUCTS

able to make better decisionsmdashespecially in the case of the unexpected ldquoWhen a shipment is held up at the portrdquo says Prashant Bhatia director of solutions management at SAP ldquoit can trigger logic back to say that Irsquove got a problem I can no longer allocate that inventory on that particular shipment as I thought I couldrdquo

3 One database one system one supply chain In the last few years soft-ware providers have been pulling all of their products onto a single supply chain process platform ldquoItrsquos fairly newrdquo says Lamphier ldquoVarious components have been integrated into that supply chain process platform longer than others but actually moving our WMS onto it has been a more recent developmentmdashjust within the last quarter or twordquo

SAP uses its enterprise resource planning (ERP) system as the central repository of information of supply and demand as well as inventory for the entire supply chain And the modules all

talk to each other Transportation man-agement systems (TMS) in conjunction with the event management modules help optimize freight determine pick-up windows determine carriers keep track of in-transit times and create ASNs

That ASN not only gets sent back to the ERP for visibility but it also gets sent to the WMS where the sys-tem uses the information to plan labor equipment and resources at the receiv-ing dock When the physical product arrives logic within the WMS based on the receipt of goods determines matches against actual demand

Smarter speedier equipment With more retailers crossdocking

over 50 of their items at the case level to their stores equipment innovations have centered on conveyor sortation systems print and apply mechanisms and automatic identifi cation technolo-gies Here are three new equipment

advances1 Smaller gaps and self-regulat-

ing conveyors In the last year the sliding shoe sorter has undergone note-worthy transformations ldquoBy doing a par-allel divert we can now run the packages closer together and get a higher through-put on the same systemrdquo reports Ken Ruehrdanz manager for Dematicrsquos distri-bution and warehousing markets

The sliding shoes that used to physi-cally push the cartons off the sorter at an angle can now run those shoes in parallel enabling smaller gaps between cartonsmdashwhich were previously from 6 inches to 8 inchesmdashdown to 3 inches

With more dense traffi c on conveyors crossdock operators can run their con-veyors at a lower speed while still achiev-ing the same throughput Slower speeds equal less wear and tear decreased energy usage and less maintenance

Another conveyor breakthrough is automatic speed control ldquoThe whole

m m h c o m MODERN MATERIALS HANDLING A P R I L 2 0 1 0 49S

MMH100401sup_Crossdock_ID 49 482010 113620 AM

Leading customers are investing in software and automated

systems to improve business according to attendees of the

Supply Chain Reset conference

mmh1010_newsindd 12 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 13

THE INDUSTRIAL REAL ESTATEmarket is taking steps in the right direction according to a report recently issued by global real estate fi rm Jones Lang LaSalle (JLL wwwjoneslanglasallecom) which report-ed the national average vacancy rate for the North American industrial real estate sector fell from 106 in the fi rst quarter to 104 in the second quarter Despite the slight decline in vacancy the fragile economy still looms large due to declining con-sumer confi dence the drying up of economic stimulus funding and the potential threat of a double-dip recession the report noted

ldquoWe have seen a positive absorp-tion in the vacancy rate in the second quarter but we are very concerned

going forwardrdquo Craig Meyer managing director and leader of JLLrsquos Logistics and Industrial Services Group told Modern ldquoAny kind of sustained demand-driven component in the industrial real estate market is going to be driven by jobs We are just not seeing any of that It is going to be a long slow recoveryrdquo

Looking at base indicators like the Institute of Supply Managementrsquos Manufacturing Index Consumer Confi dence data and industrial real estate vacancy and absorption rates there does not appear to be what Meyer labeled as a strong indication of a positive upswing on the horizon

The report says that a need to restock inventories that were running at 50-year lows resulted in large com-panies strategically capturing high

quality logistics space at cyclically low rates And with slow levels of leasing activity and sparse construc-tion industrial real estate optionsmdashespecially in the Class A large block sectormdashare limited in some markets

And the swift correction in invento-ries during the second half of 2009 and fi rst quarter of 2010 has left inventory levels lean and ready for expansion provided sales rebound in the coming months Should this occur it could lead to increased industrial and logistics real estate leasing activity

The report also pointed out that the initial recovery in the economy was largely driven by improvements in the manufacturing sector and cyclical adjustments in inventories But with the recovery now becoming more broad-based the recent slowdown of inven-tory building could have more of an impact on the industrial property sector than the offi ce sector the report noted

Date 090910 Client Rehrig Pacifi c Job 08312010 File Name 0831_RPC_SlipSheet_Ad_MMH_Oct10 Round

Account Director Niki Phan Designer Revised By ov Editor Production ov

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Publication(s) TBD Run Date(s) TBD

Approved By

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Available in standard or custom sizes with a variety of surface textures and embossed patterns Rehrig Slip Sheets provide superior slide resistance keeping goods securely in place Manufactured from nearly 100 recycled material each sheet is also 100 recyclable

Beyond the sale Rehrig can help you develop a customized re-use or buy-back program further lowering your average cost per trip

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WAREHOUSESDCS

Industrial real estate market making progress challenges remain

mmh1010_newsindd 13 101310 1049 AM

14 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

ldquoWe are also concerned about seasonality with the holiday season coming uprdquo said Meyer ldquoThe indica-tions we are getting are that we may not see as much preparation for that as we hoped A lot of retailers are saying they are restocked and if consumer confi dence is going down they are not going to build up inventories And for larger big box companies they will see declining values in rents but the availability of product for them to lease is diminishingrdquo

As a result Class A big box dis-tribution space is becoming more diffi cult to fi nd in this economy said Meyer But the build-to-suit market could come back for major retailers as evidenced by a new 1-million-square-foot DC space deal by Amazoncom in Harrisburg Pa and a 14-million-square-foot location in Phoenix

But for a mid-sized industrial building in the 100000-to-150000-square-foot range Class B-sized build-

ing Meyer said there are an infi nite number of these on the market

Looking ahead Meyer said there will still be downward pressure on pric-

ing a double-digit vacancy rate and no increases in lease rates which he noted are actually weakening a little bit and tend to lag a recovery

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BFL AD MMH APRIL 92710 358 PM Page 1

CROWN EQUIPMENT Corp has quali-fi ed 20 of its electric models to operate with various fuel cells bringing the total of qualifi ed combinations of fuel cell packs and trucks to 29 In 2009 Crown (wwwcrowncom) was the fi rst lift truck manufacturer to introduce a fuel cell qualifi cation program

Eric Jensen Crownrsquos manager of new technology research and de-velopment told Modern that the companyrsquos fuel cell qualifi cation pro-gram duplicates its own testing and is conducted at a 25000-square-foot research facility near Dayton Ohio Through the testing process engi-

neers evaluate fuel cell performance and monitor whether issues develop that affect the truckrsquos operation

To qualify a fuel cell pack and truck combination Crownrsquos engineers review key performance metrics for a battery-powered truck such as traction plug-ging and lift and travel speeds Then they replace the battery with a fuel cell power pack and measure the same indicators Through modeling and ap-plication testing the research team de-termines design modifi cations needed to ensure the fuel cell-powered forklift matched standards to which the truck was designed

LIFT TRUCKS

Crown unveils 20 electric lift trucks to operate with fuel cells

mmh1010_newsindd 14 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 15

ldquoWersquove been steadfast in our posi-tion that deployment of a fuel cell forklift fl eet must be carefully evalu-ated and tested for appropriate use in a warehouserdquo said Jensen ldquoThis research-based approach means that our customers can confi dently know they have the right truck for their chosen fuel cell allowing them to meet their performance safety and

environmental sus-tainability goalsrdquo

Crown continues to work closely with fuel cell manufactur-ers and customers to qualify trucks as new fuel cell pack models are intro-duced ldquoForklifts are a key early market for fuel cellsrdquo said Lisa Callaghan Jerram senior market analyst for Fuel Cell Today a leading analyst

fi rm providing market-based research on the fuel cell industry ldquoBased on our market research we have found strong growth in this sector in the past three yearsrdquo

Because fuel cell powered electric forklifts give off exhaust in the form of moist warm air IC truck custom-ers are looking to this technology

so they donrsquot have to deal exhaust issues Jensen said Another advan-tage pointed out by Jensen is a fuel cell powered truckrsquos ability to effec-tively operate in a cold environment because they generate their own heat and the power doesnrsquot fall off like a traditional battery

While the upfront hardware cost of fuel cells is more expensive than a traditional battery Jensen pointed out the potential to capture savings in labor battery changes battery rooms and heating and venting With fuel cells he said a facility doesnrsquot need a battery room and all that goes in to running it properly Instead there is an ongoing savings associated to using fl oor space for production or other value-added operations

ldquoFuel cells have always been talked about fi ve years into the future but we have customers who are [currently] planning installations around this prod-uctrdquo said Jensen ldquoThe future is hererdquo

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To qualify a fuel cell pack and truck combination engineers

review key performance metrics

mmh1010_newsindd 15 101310 1049 AM

lift truck TIPS

GraphicCaption

In the right application tuggers and carts can be a fast and efficient solution

Level the playing field

Football season is under-way and fans are hoping for breakout performances

from stars and rookies alike On the gridiron an overpowered player can be a distinct advan-tage In the warehouse how-ever too much power can lead to waste danger and sluggish performance For some corpo-rations this fact has prompted consideration of fork-free envi-ronments where versatile and custom-built carts and tuggers can do the work faster and more efficiently than their big-ger cousins

Disposing of expensive and powerful equipment in favor of carts may seem counter-intuitive but Jill Burrow marketing manager for Topper Industrial says certain warehouses might benefit greatly from the switch For operations requiring multiple trips between the same areas carts can cut travel time sig-nificantly According to Ed Brown president of Topper Industrial a tugger can pull as many as 13 carts In addi-tion says Brown carts and tuggers can be easier to use than many forklifts

ldquoA forklift costs five times as much but a forklift opera-tor also costs five times more than a tugger operatorrdquo says Brown ldquoAnyone can grab a tugger and gordquo

Once a forklift drops off a pallet in many cases a picker must bend to access product or arrange for the pallet to be lifted Carts on the other hand can be configured with swiveling or angled platforms to allow pickers fast and comfortable access to products Worker safety issues tied to forklifts that operate in tight areas such as poor visibility when driving in re-verse and dock mishaps can also be greatly reduced

ldquoCompanies looking at carts are looking at the cost of equipment and the cost of maintenance but theyrsquore also looking at safetyrdquo says Brown

In addition to ergonomics and safety a fork-free zone might help a warehouse reduce product loss and equip-ment damage Carts provide a secure cradle for moving product while some fork-borne loads are prone to top-pling And forklifts often 10 times as heavy as a tugger and cart setup have a way of proving their strength by leaving dings and dents on storage racks and other hap-less stationary objects

With carts and tuggers Brown says most companies see a return on investment within a year In football a first-round draft pick can cost millions over a multi-year contract before he produces the desired results For com-panies not looking to attempt such a Hail Mary tuggers could prove an efficient alternative

Josh Bond is a contributing editor to Modern and can be reached at turbobondgmailcom

16 O c t O b e r 2 0 1 0 Modern Materials Handling m m h c o m

lift truck TIPS

By Josh Bond Contributing Editor

MMH1010_LiftTruckTipsindd 16 101310 942 AM

MM100601Adsindd 3 6310 349 PMMMH1010_Adsindd 17 101210 1053 AM

18 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

Keith arntson vice president of distribution operations for

del Monte Foods

Four conveyor-topped vehicles ferry loads from an adjacent manufacturing plant

MMH1010_SystemRptDelMonteindd 18 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

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Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

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Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

bull Discover the newest robotics products and services bull See the latest robot-based solutions for picking and palletizing bull Understand how intelligent robots are revolutionizing processing

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ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

Denso RoboticsElite EngineeringFANUC RoboticsFood EngineeringGenesis Systems GroupHartness InternationalKIva Systems

Modern Materials HandlingMotion Control RoboticsNational InstrumentsOmron Scientifi c Technologies IncRobotics TrendsWind RiverYaskawa Motoman Robotics

MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

chepcomsimplechoice

Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

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48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

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MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

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Holster YourSide Arm

or a slingerright or left

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LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

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jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 11: Modern Materials Handling - October 2010

middot Robotic palletizing cells handle goods at the end of the production linemiddot LGVs transport pallets to stretch wrapping and labelingmiddot LGVs transport finished pallets to the warehousemiddot LGVs for Storage amp Retrieval (SRS)middot LGVs for Auto-Trailer Loading (ATL)middot An integrated software management system

Elettric 80 is a global provider of end-of-lineautomation solutions These solutions are called Freewayreg material handling system

The technologies are adaptable and have a high degree of built-in flexibility which makes them suitable for any plant warehouse layout or design More details explanatory videos and animations can be found at wwwelettric80com

ITALY middot USA middot SWEDEN middot UK middot AUSTRALIA middot POLAND

Elettric 80 Inc8100 Monticello AvenueSkokie IL 60076 USAPhone +1 847 329 7717e80usaelettric80it

Freewayreg is based on a simple idea

C

M

Y

CM

MY

CY

CMY

K

el80_US_verticalpdf 1 2010-09-29 1346

chain application suite which spans from supplier to store shelf and includes warehouse management systems transportation management systems route accounting systems manufacturing execution mobile sales and ERP data collection Trading partner collaboration is increas-ingly important as organizations strive to reduce costs and improve service levels By combining integration solutions with application functionality organizations are able to ensure consistency in business processes and accuracy of information exchanged with trading partners

ldquoTrueCommerce has fi lled a unique need in the market for simple robust and affordable EDI solutions for small and midsized businessesrdquo said Nick Manolis TrueCom-merce CEO ldquoI am excited for the TrueCommerce team to join HighJump while continuing to provide excellent service support and product innovation to our customersrdquo

ldquoCombining HighJump and TrueCommerce creates a unique and compelling solution offering within the supply chain software marketrdquo said Russell Fleischer HighJump Software CEO ldquoOur view is that supply chain applications must allow users to connect with a broad ecosystem of trading partners to maximize value The TrueCommerce solution platform and our previous move to cloud-based applications will help translate this vision into reality for our customersrdquo

SUPPLY CHAIN NEWS ANALYSIS

Final thoughts on Supply Chain Reset conferenceBY BOB TREBILCOCK EXECUTIVE EDITOR

DESPITE SIGNS OF IMPROVEMENTS doing business in in materials handling remains a challenge At the same time many of the leading customers are investing in supply chain software and automated materials handling systems to improve their businesses That suggests better times are coming

Tom Brokaw punctuates the 25th anniversary of the Material

Handling and Logistics Conference by HK Systems

mmh1010_newsindd 10 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 11

Leader of the PackThe originator of high speed narrow belt sortationTGW Systems has led the way in offering provenadvantages over conventional sortation for over 10 years

NBS fromTGW Systems

50 less install time60 less energy75 less noise

100 of the Value

wwwtgw-groupcom

TGW Systems (formerly TGW-Ermanco) is an integrated logistics solutions and material handling equipment provider The Ermanco name lives onas the product family name for the conveying andsortation products manufactured in the US

Our worldwide perspective and resources and commitment to innovation product developmentand unparalleled customer service can help you today

Proven track record ndash Over 700 installations around the world have made TGWrsquos Narrow Belt Sorter one of the most reliable sorters available

Rugged durability ndash TGWrsquos NBS sorters operate in some of the harshest distribution environments in the world earning customerrsquos admiration and competitorrsquos respect

Application and layout fl exibility ndash The universal frame on TGWrsquos narrow belt sorter means you can use multiple divert options and easily add divert modules after installation for increased fl exibility

Patented technology ndash Patented sortation technology in the TGWrsquos narrow belt sorter continues to lead the way in effective energy effi cient fl exible sortation

10 08 NBSindd 1 8302010 34008 PM

keep enough labor to run his primary distribution center Two presentations drove this point home The fi rst was from an executive with Tim Hor-tons the Dunkin Donuts of Canada The companyrsquos beautiful new DC in Guelph Ontario is underperforming projections even though the ASRS is

living up to its promises The reason The company canrsquot fi nd enough labor willing to work in its case picking and palletizing operations The other was by Terra Winston a consultant who presented a case study about a proj-ect at PepsiCo to develop the next wave of supply chain leaders Her

Those are the two high level take-aways from Supply Chain Reset the annual logistics conference held last month in Park City Utah sponsored by HK Systems now part of Dematic

ldquoLousyrdquo was the most common response to the dinner-time question ldquoHowrsquos businessrdquo

At the same time the roll call of end user companies that said they had projects in the works or on the drawing board was both a Whorsquos Who of American business with names like Coca-Cola and Kraft and companies many of us may never have heard of or think of as custom-ers of our solutions For example I sat on the van from the airport with a guy from the Los Angeles metro-politan transportation system looking for a new automated storage and retrieval system (ASRS) The Federal Reserve Bank was there investigat-ing storage systems I rode in the van back to the airport with a woman from a producer of honey in Texas who had both an ASRS and auto-matic guided vehicles in her facil-ity and was looking to expand her system

Those are signs of a growing con-fi dence I donrsquot think companies plan multi-million dollar investments in au-tomation if they think the apocalypse is right around the corner

One other anecdotal data point Marc Ducharme a vice president and partner with Axium a supplier of robotic materials handling solu-tions told me that 2009 was a dismal year for implementations but that his company has been swamped with RFPs in 2010 An RFP is not an order but itrsquos a sign

A few other observationsRetaining labor and talent could

be the most important issue facing the industry in the future A week or so before going to Utah I had a con-versation with a vice president of sup-ply chain for a major retailer who told me he is interested in automation because he simply cannot fi nd and

mmh1010_newsindd 11 101310 1049 AM

12 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

point the talent shortage isnrsquot limited just to the shop fl oor

Retrofi tting is a viable solution You know the old saying Every-thing old is new again Wegmanrsquos a Midwestern grocer and Rubber-maid both gave strong presenta-tions about how they replaced ag-ing ASRS cranes to breathe new life into their DCs Meanwhile Anheuser Busch gained new ef-fi ciencies in its Columbus Ohio facility by upgrading a warehouse control system

Everyone loves pallets Based in Iowa Green Line Armor is offering a heavy-duty hybrid woodplastic pallet for permanent pallet pools The 48- x 40-inch pallet has heavier stringers and more deck board coverage than a grocery pallet The lead boards on the top and the bottom of the palletmdashthose most likely to get damaged by a lift truckmdashare manufactured from heavy plastic The pallet has a passive RFID

tag that is used by Green Line Armor to identify the pallet and manage war-ranty services Active RFID tags were installed for John Deere the companyrsquos largest customer to track the location of work in process stored on the pallets between manufacturing processes Eric Renteria the companyrsquos president said the pallets which come with a 10-year warranty can be purchased or leased

in a pooling modelNew players are get-

ting into automation Kip Tygard whose company makes the Tygard Claw a lift truck attachment for mixed case palletizing is investing RampD money to develop an automated version of the Claw Thatrsquos not a big shock Tygard is an OEM But I also had conversations with two very large end users in the wholesale food distribu-

tion business that have designed their own automated systemsmdashone has built and implemented its own ASRS design for freezers for years the other has designed its own case picking application that it intends to put out for bid to the materials handling community Both say they may commercialize their solutions in the future

VERSATILITY MATTERSQuality Wildeck construction and versatility make the V-lifttrade the ultimate lifting solution

In todayrsquos lsquogreenrsquo building designs floor space is at a premium and moving up not out is definitely preferred Look no further than the V-Lifttrade from Wildeck ndash the industry leader in space optimization The single cylinder hydraulic system eliminates all moving hoses cables and chains Fewer components means easy installation reduced maintenance and longer service life To get more value out of your operation contact a Wildeck representative today

copyWildeck Inc 2010 Required safety gates and guarding removed for clarity

800-325-6939 | WWWWILDECKCOM

MEZZANINESCapacity Matters Efficiency Matters

LIFT SYSTEMSSafety MattersGUARDING PRODUCTS

able to make better decisionsmdashespecially in the case of the unexpected ldquoWhen a shipment is held up at the portrdquo says Prashant Bhatia director of solutions management at SAP ldquoit can trigger logic back to say that Irsquove got a problem I can no longer allocate that inventory on that particular shipment as I thought I couldrdquo

3 One database one system one supply chain In the last few years soft-ware providers have been pulling all of their products onto a single supply chain process platform ldquoItrsquos fairly newrdquo says Lamphier ldquoVarious components have been integrated into that supply chain process platform longer than others but actually moving our WMS onto it has been a more recent developmentmdashjust within the last quarter or twordquo

SAP uses its enterprise resource planning (ERP) system as the central repository of information of supply and demand as well as inventory for the entire supply chain And the modules all

talk to each other Transportation man-agement systems (TMS) in conjunction with the event management modules help optimize freight determine pick-up windows determine carriers keep track of in-transit times and create ASNs

That ASN not only gets sent back to the ERP for visibility but it also gets sent to the WMS where the sys-tem uses the information to plan labor equipment and resources at the receiv-ing dock When the physical product arrives logic within the WMS based on the receipt of goods determines matches against actual demand

Smarter speedier equipment With more retailers crossdocking

over 50 of their items at the case level to their stores equipment innovations have centered on conveyor sortation systems print and apply mechanisms and automatic identifi cation technolo-gies Here are three new equipment

advances1 Smaller gaps and self-regulat-

ing conveyors In the last year the sliding shoe sorter has undergone note-worthy transformations ldquoBy doing a par-allel divert we can now run the packages closer together and get a higher through-put on the same systemrdquo reports Ken Ruehrdanz manager for Dematicrsquos distri-bution and warehousing markets

The sliding shoes that used to physi-cally push the cartons off the sorter at an angle can now run those shoes in parallel enabling smaller gaps between cartonsmdashwhich were previously from 6 inches to 8 inchesmdashdown to 3 inches

With more dense traffi c on conveyors crossdock operators can run their con-veyors at a lower speed while still achiev-ing the same throughput Slower speeds equal less wear and tear decreased energy usage and less maintenance

Another conveyor breakthrough is automatic speed control ldquoThe whole

m m h c o m MODERN MATERIALS HANDLING A P R I L 2 0 1 0 49S

MMH100401sup_Crossdock_ID 49 482010 113620 AM

Leading customers are investing in software and automated

systems to improve business according to attendees of the

Supply Chain Reset conference

mmh1010_newsindd 12 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 13

THE INDUSTRIAL REAL ESTATEmarket is taking steps in the right direction according to a report recently issued by global real estate fi rm Jones Lang LaSalle (JLL wwwjoneslanglasallecom) which report-ed the national average vacancy rate for the North American industrial real estate sector fell from 106 in the fi rst quarter to 104 in the second quarter Despite the slight decline in vacancy the fragile economy still looms large due to declining con-sumer confi dence the drying up of economic stimulus funding and the potential threat of a double-dip recession the report noted

ldquoWe have seen a positive absorp-tion in the vacancy rate in the second quarter but we are very concerned

going forwardrdquo Craig Meyer managing director and leader of JLLrsquos Logistics and Industrial Services Group told Modern ldquoAny kind of sustained demand-driven component in the industrial real estate market is going to be driven by jobs We are just not seeing any of that It is going to be a long slow recoveryrdquo

Looking at base indicators like the Institute of Supply Managementrsquos Manufacturing Index Consumer Confi dence data and industrial real estate vacancy and absorption rates there does not appear to be what Meyer labeled as a strong indication of a positive upswing on the horizon

The report says that a need to restock inventories that were running at 50-year lows resulted in large com-panies strategically capturing high

quality logistics space at cyclically low rates And with slow levels of leasing activity and sparse construc-tion industrial real estate optionsmdashespecially in the Class A large block sectormdashare limited in some markets

And the swift correction in invento-ries during the second half of 2009 and fi rst quarter of 2010 has left inventory levels lean and ready for expansion provided sales rebound in the coming months Should this occur it could lead to increased industrial and logistics real estate leasing activity

The report also pointed out that the initial recovery in the economy was largely driven by improvements in the manufacturing sector and cyclical adjustments in inventories But with the recovery now becoming more broad-based the recent slowdown of inven-tory building could have more of an impact on the industrial property sector than the offi ce sector the report noted

Date 090910 Client Rehrig Pacifi c Job 08312010 File Name 0831_RPC_SlipSheet_Ad_MMH_Oct10 Round

Account Director Niki Phan Designer Revised By ov Editor Production ov

Color 4CProcess Trim 7 times 4625 Bleed 0 Safety 675times 4375 Fold na

Publication(s) TBD Run Date(s) TBD

Approved By

A FAMILY TRADITION OF GROWTH SERVICE AND INNOVATION

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Ship more product per load with Rehrigrsquos weight space and cost saving Slip Sheets

Rehrig co-extruded Slip Sheets are a cost-effective alternative to pallets Impervious to moisture high tensile strength plastic provides added tear resistance making them the perfect replacement for fi ber or corrugated sheets as well

Available in standard or custom sizes with a variety of surface textures and embossed patterns Rehrig Slip Sheets provide superior slide resistance keeping goods securely in place Manufactured from nearly 100 recycled material each sheet is also 100 recyclable

Beyond the sale Rehrig can help you develop a customized re-use or buy-back program further lowering your average cost per trip

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WAREHOUSESDCS

Industrial real estate market making progress challenges remain

mmh1010_newsindd 13 101310 1049 AM

14 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

ldquoWe are also concerned about seasonality with the holiday season coming uprdquo said Meyer ldquoThe indica-tions we are getting are that we may not see as much preparation for that as we hoped A lot of retailers are saying they are restocked and if consumer confi dence is going down they are not going to build up inventories And for larger big box companies they will see declining values in rents but the availability of product for them to lease is diminishingrdquo

As a result Class A big box dis-tribution space is becoming more diffi cult to fi nd in this economy said Meyer But the build-to-suit market could come back for major retailers as evidenced by a new 1-million-square-foot DC space deal by Amazoncom in Harrisburg Pa and a 14-million-square-foot location in Phoenix

But for a mid-sized industrial building in the 100000-to-150000-square-foot range Class B-sized build-

ing Meyer said there are an infi nite number of these on the market

Looking ahead Meyer said there will still be downward pressure on pric-

ing a double-digit vacancy rate and no increases in lease rates which he noted are actually weakening a little bit and tend to lag a recovery

Power AND CoNtrol

Introducing the latest innovations for incorporating Power AND Control into

your 24 VDC conveyor system

For over 60 years Itoh Denki has been the proven leader in the development and manufacture of superior motorized rollers and components This history provides you confidence in your 24V conveyor applications and designs a confidence based on the component integrity offered by the only sole source motor and control manufacturer in the industry

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LIFTrdquoBFL lifts are designed to move large loads ormultiple pallets betweenfloors These lifts willtravel from 8 feet to 18feet and have platformsizes ranging from 6rsquo x 8rsquo up to 8rsquo x 12rsquoThey are ideal for movinglarge loads 1-2 floors orup to high stages andmezzanines

1-800-843-3625wwwadvancel i f ts com

BFL AD MMH APRIL 92710 358 PM Page 1

CROWN EQUIPMENT Corp has quali-fi ed 20 of its electric models to operate with various fuel cells bringing the total of qualifi ed combinations of fuel cell packs and trucks to 29 In 2009 Crown (wwwcrowncom) was the fi rst lift truck manufacturer to introduce a fuel cell qualifi cation program

Eric Jensen Crownrsquos manager of new technology research and de-velopment told Modern that the companyrsquos fuel cell qualifi cation pro-gram duplicates its own testing and is conducted at a 25000-square-foot research facility near Dayton Ohio Through the testing process engi-

neers evaluate fuel cell performance and monitor whether issues develop that affect the truckrsquos operation

To qualify a fuel cell pack and truck combination Crownrsquos engineers review key performance metrics for a battery-powered truck such as traction plug-ging and lift and travel speeds Then they replace the battery with a fuel cell power pack and measure the same indicators Through modeling and ap-plication testing the research team de-termines design modifi cations needed to ensure the fuel cell-powered forklift matched standards to which the truck was designed

LIFT TRUCKS

Crown unveils 20 electric lift trucks to operate with fuel cells

mmh1010_newsindd 14 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 15

ldquoWersquove been steadfast in our posi-tion that deployment of a fuel cell forklift fl eet must be carefully evalu-ated and tested for appropriate use in a warehouserdquo said Jensen ldquoThis research-based approach means that our customers can confi dently know they have the right truck for their chosen fuel cell allowing them to meet their performance safety and

environmental sus-tainability goalsrdquo

Crown continues to work closely with fuel cell manufactur-ers and customers to qualify trucks as new fuel cell pack models are intro-duced ldquoForklifts are a key early market for fuel cellsrdquo said Lisa Callaghan Jerram senior market analyst for Fuel Cell Today a leading analyst

fi rm providing market-based research on the fuel cell industry ldquoBased on our market research we have found strong growth in this sector in the past three yearsrdquo

Because fuel cell powered electric forklifts give off exhaust in the form of moist warm air IC truck custom-ers are looking to this technology

so they donrsquot have to deal exhaust issues Jensen said Another advan-tage pointed out by Jensen is a fuel cell powered truckrsquos ability to effec-tively operate in a cold environment because they generate their own heat and the power doesnrsquot fall off like a traditional battery

While the upfront hardware cost of fuel cells is more expensive than a traditional battery Jensen pointed out the potential to capture savings in labor battery changes battery rooms and heating and venting With fuel cells he said a facility doesnrsquot need a battery room and all that goes in to running it properly Instead there is an ongoing savings associated to using fl oor space for production or other value-added operations

ldquoFuel cells have always been talked about fi ve years into the future but we have customers who are [currently] planning installations around this prod-uctrdquo said Jensen ldquoThe future is hererdquo

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Subject to credit approval

To qualify a fuel cell pack and truck combination engineers

review key performance metrics

mmh1010_newsindd 15 101310 1049 AM

lift truck TIPS

GraphicCaption

In the right application tuggers and carts can be a fast and efficient solution

Level the playing field

Football season is under-way and fans are hoping for breakout performances

from stars and rookies alike On the gridiron an overpowered player can be a distinct advan-tage In the warehouse how-ever too much power can lead to waste danger and sluggish performance For some corpo-rations this fact has prompted consideration of fork-free envi-ronments where versatile and custom-built carts and tuggers can do the work faster and more efficiently than their big-ger cousins

Disposing of expensive and powerful equipment in favor of carts may seem counter-intuitive but Jill Burrow marketing manager for Topper Industrial says certain warehouses might benefit greatly from the switch For operations requiring multiple trips between the same areas carts can cut travel time sig-nificantly According to Ed Brown president of Topper Industrial a tugger can pull as many as 13 carts In addi-tion says Brown carts and tuggers can be easier to use than many forklifts

ldquoA forklift costs five times as much but a forklift opera-tor also costs five times more than a tugger operatorrdquo says Brown ldquoAnyone can grab a tugger and gordquo

Once a forklift drops off a pallet in many cases a picker must bend to access product or arrange for the pallet to be lifted Carts on the other hand can be configured with swiveling or angled platforms to allow pickers fast and comfortable access to products Worker safety issues tied to forklifts that operate in tight areas such as poor visibility when driving in re-verse and dock mishaps can also be greatly reduced

ldquoCompanies looking at carts are looking at the cost of equipment and the cost of maintenance but theyrsquore also looking at safetyrdquo says Brown

In addition to ergonomics and safety a fork-free zone might help a warehouse reduce product loss and equip-ment damage Carts provide a secure cradle for moving product while some fork-borne loads are prone to top-pling And forklifts often 10 times as heavy as a tugger and cart setup have a way of proving their strength by leaving dings and dents on storage racks and other hap-less stationary objects

With carts and tuggers Brown says most companies see a return on investment within a year In football a first-round draft pick can cost millions over a multi-year contract before he produces the desired results For com-panies not looking to attempt such a Hail Mary tuggers could prove an efficient alternative

Josh Bond is a contributing editor to Modern and can be reached at turbobondgmailcom

16 O c t O b e r 2 0 1 0 Modern Materials Handling m m h c o m

lift truck TIPS

By Josh Bond Contributing Editor

MMH1010_LiftTruckTipsindd 16 101310 942 AM

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18 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

Keith arntson vice president of distribution operations for

del Monte Foods

Four conveyor-topped vehicles ferry loads from an adjacent manufacturing plant

MMH1010_SystemRptDelMonteindd 18 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

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Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

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MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

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Holster YourSide Arm

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LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

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Label Holders Load Transfer Systems

Career Opportunities

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Donrsquot Cost - They Pay

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VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

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Ergonomic Holster systems

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career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

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bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

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As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 12: Modern Materials Handling - October 2010

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 11

Leader of the PackThe originator of high speed narrow belt sortationTGW Systems has led the way in offering provenadvantages over conventional sortation for over 10 years

NBS fromTGW Systems

50 less install time60 less energy75 less noise

100 of the Value

wwwtgw-groupcom

TGW Systems (formerly TGW-Ermanco) is an integrated logistics solutions and material handling equipment provider The Ermanco name lives onas the product family name for the conveying andsortation products manufactured in the US

Our worldwide perspective and resources and commitment to innovation product developmentand unparalleled customer service can help you today

Proven track record ndash Over 700 installations around the world have made TGWrsquos Narrow Belt Sorter one of the most reliable sorters available

Rugged durability ndash TGWrsquos NBS sorters operate in some of the harshest distribution environments in the world earning customerrsquos admiration and competitorrsquos respect

Application and layout fl exibility ndash The universal frame on TGWrsquos narrow belt sorter means you can use multiple divert options and easily add divert modules after installation for increased fl exibility

Patented technology ndash Patented sortation technology in the TGWrsquos narrow belt sorter continues to lead the way in effective energy effi cient fl exible sortation

10 08 NBSindd 1 8302010 34008 PM

keep enough labor to run his primary distribution center Two presentations drove this point home The fi rst was from an executive with Tim Hor-tons the Dunkin Donuts of Canada The companyrsquos beautiful new DC in Guelph Ontario is underperforming projections even though the ASRS is

living up to its promises The reason The company canrsquot fi nd enough labor willing to work in its case picking and palletizing operations The other was by Terra Winston a consultant who presented a case study about a proj-ect at PepsiCo to develop the next wave of supply chain leaders Her

Those are the two high level take-aways from Supply Chain Reset the annual logistics conference held last month in Park City Utah sponsored by HK Systems now part of Dematic

ldquoLousyrdquo was the most common response to the dinner-time question ldquoHowrsquos businessrdquo

At the same time the roll call of end user companies that said they had projects in the works or on the drawing board was both a Whorsquos Who of American business with names like Coca-Cola and Kraft and companies many of us may never have heard of or think of as custom-ers of our solutions For example I sat on the van from the airport with a guy from the Los Angeles metro-politan transportation system looking for a new automated storage and retrieval system (ASRS) The Federal Reserve Bank was there investigat-ing storage systems I rode in the van back to the airport with a woman from a producer of honey in Texas who had both an ASRS and auto-matic guided vehicles in her facil-ity and was looking to expand her system

Those are signs of a growing con-fi dence I donrsquot think companies plan multi-million dollar investments in au-tomation if they think the apocalypse is right around the corner

One other anecdotal data point Marc Ducharme a vice president and partner with Axium a supplier of robotic materials handling solu-tions told me that 2009 was a dismal year for implementations but that his company has been swamped with RFPs in 2010 An RFP is not an order but itrsquos a sign

A few other observationsRetaining labor and talent could

be the most important issue facing the industry in the future A week or so before going to Utah I had a con-versation with a vice president of sup-ply chain for a major retailer who told me he is interested in automation because he simply cannot fi nd and

mmh1010_newsindd 11 101310 1049 AM

12 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

point the talent shortage isnrsquot limited just to the shop fl oor

Retrofi tting is a viable solution You know the old saying Every-thing old is new again Wegmanrsquos a Midwestern grocer and Rubber-maid both gave strong presenta-tions about how they replaced ag-ing ASRS cranes to breathe new life into their DCs Meanwhile Anheuser Busch gained new ef-fi ciencies in its Columbus Ohio facility by upgrading a warehouse control system

Everyone loves pallets Based in Iowa Green Line Armor is offering a heavy-duty hybrid woodplastic pallet for permanent pallet pools The 48- x 40-inch pallet has heavier stringers and more deck board coverage than a grocery pallet The lead boards on the top and the bottom of the palletmdashthose most likely to get damaged by a lift truckmdashare manufactured from heavy plastic The pallet has a passive RFID

tag that is used by Green Line Armor to identify the pallet and manage war-ranty services Active RFID tags were installed for John Deere the companyrsquos largest customer to track the location of work in process stored on the pallets between manufacturing processes Eric Renteria the companyrsquos president said the pallets which come with a 10-year warranty can be purchased or leased

in a pooling modelNew players are get-

ting into automation Kip Tygard whose company makes the Tygard Claw a lift truck attachment for mixed case palletizing is investing RampD money to develop an automated version of the Claw Thatrsquos not a big shock Tygard is an OEM But I also had conversations with two very large end users in the wholesale food distribu-

tion business that have designed their own automated systemsmdashone has built and implemented its own ASRS design for freezers for years the other has designed its own case picking application that it intends to put out for bid to the materials handling community Both say they may commercialize their solutions in the future

VERSATILITY MATTERSQuality Wildeck construction and versatility make the V-lifttrade the ultimate lifting solution

In todayrsquos lsquogreenrsquo building designs floor space is at a premium and moving up not out is definitely preferred Look no further than the V-Lifttrade from Wildeck ndash the industry leader in space optimization The single cylinder hydraulic system eliminates all moving hoses cables and chains Fewer components means easy installation reduced maintenance and longer service life To get more value out of your operation contact a Wildeck representative today

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MEZZANINESCapacity Matters Efficiency Matters

LIFT SYSTEMSSafety MattersGUARDING PRODUCTS

able to make better decisionsmdashespecially in the case of the unexpected ldquoWhen a shipment is held up at the portrdquo says Prashant Bhatia director of solutions management at SAP ldquoit can trigger logic back to say that Irsquove got a problem I can no longer allocate that inventory on that particular shipment as I thought I couldrdquo

3 One database one system one supply chain In the last few years soft-ware providers have been pulling all of their products onto a single supply chain process platform ldquoItrsquos fairly newrdquo says Lamphier ldquoVarious components have been integrated into that supply chain process platform longer than others but actually moving our WMS onto it has been a more recent developmentmdashjust within the last quarter or twordquo

SAP uses its enterprise resource planning (ERP) system as the central repository of information of supply and demand as well as inventory for the entire supply chain And the modules all

talk to each other Transportation man-agement systems (TMS) in conjunction with the event management modules help optimize freight determine pick-up windows determine carriers keep track of in-transit times and create ASNs

That ASN not only gets sent back to the ERP for visibility but it also gets sent to the WMS where the sys-tem uses the information to plan labor equipment and resources at the receiv-ing dock When the physical product arrives logic within the WMS based on the receipt of goods determines matches against actual demand

Smarter speedier equipment With more retailers crossdocking

over 50 of their items at the case level to their stores equipment innovations have centered on conveyor sortation systems print and apply mechanisms and automatic identifi cation technolo-gies Here are three new equipment

advances1 Smaller gaps and self-regulat-

ing conveyors In the last year the sliding shoe sorter has undergone note-worthy transformations ldquoBy doing a par-allel divert we can now run the packages closer together and get a higher through-put on the same systemrdquo reports Ken Ruehrdanz manager for Dematicrsquos distri-bution and warehousing markets

The sliding shoes that used to physi-cally push the cartons off the sorter at an angle can now run those shoes in parallel enabling smaller gaps between cartonsmdashwhich were previously from 6 inches to 8 inchesmdashdown to 3 inches

With more dense traffi c on conveyors crossdock operators can run their con-veyors at a lower speed while still achiev-ing the same throughput Slower speeds equal less wear and tear decreased energy usage and less maintenance

Another conveyor breakthrough is automatic speed control ldquoThe whole

m m h c o m MODERN MATERIALS HANDLING A P R I L 2 0 1 0 49S

MMH100401sup_Crossdock_ID 49 482010 113620 AM

Leading customers are investing in software and automated

systems to improve business according to attendees of the

Supply Chain Reset conference

mmh1010_newsindd 12 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 13

THE INDUSTRIAL REAL ESTATEmarket is taking steps in the right direction according to a report recently issued by global real estate fi rm Jones Lang LaSalle (JLL wwwjoneslanglasallecom) which report-ed the national average vacancy rate for the North American industrial real estate sector fell from 106 in the fi rst quarter to 104 in the second quarter Despite the slight decline in vacancy the fragile economy still looms large due to declining con-sumer confi dence the drying up of economic stimulus funding and the potential threat of a double-dip recession the report noted

ldquoWe have seen a positive absorp-tion in the vacancy rate in the second quarter but we are very concerned

going forwardrdquo Craig Meyer managing director and leader of JLLrsquos Logistics and Industrial Services Group told Modern ldquoAny kind of sustained demand-driven component in the industrial real estate market is going to be driven by jobs We are just not seeing any of that It is going to be a long slow recoveryrdquo

Looking at base indicators like the Institute of Supply Managementrsquos Manufacturing Index Consumer Confi dence data and industrial real estate vacancy and absorption rates there does not appear to be what Meyer labeled as a strong indication of a positive upswing on the horizon

The report says that a need to restock inventories that were running at 50-year lows resulted in large com-panies strategically capturing high

quality logistics space at cyclically low rates And with slow levels of leasing activity and sparse construc-tion industrial real estate optionsmdashespecially in the Class A large block sectormdashare limited in some markets

And the swift correction in invento-ries during the second half of 2009 and fi rst quarter of 2010 has left inventory levels lean and ready for expansion provided sales rebound in the coming months Should this occur it could lead to increased industrial and logistics real estate leasing activity

The report also pointed out that the initial recovery in the economy was largely driven by improvements in the manufacturing sector and cyclical adjustments in inventories But with the recovery now becoming more broad-based the recent slowdown of inven-tory building could have more of an impact on the industrial property sector than the offi ce sector the report noted

Date 090910 Client Rehrig Pacifi c Job 08312010 File Name 0831_RPC_SlipSheet_Ad_MMH_Oct10 Round

Account Director Niki Phan Designer Revised By ov Editor Production ov

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Publication(s) TBD Run Date(s) TBD

Approved By

A FAMILY TRADITION OF GROWTH SERVICE AND INNOVATION

Give Your Heavy Pallets the Slip

Material Handling

Ship more product per load with Rehrigrsquos weight space and cost saving Slip Sheets

Rehrig co-extruded Slip Sheets are a cost-effective alternative to pallets Impervious to moisture high tensile strength plastic provides added tear resistance making them the perfect replacement for fi ber or corrugated sheets as well

Available in standard or custom sizes with a variety of surface textures and embossed patterns Rehrig Slip Sheets provide superior slide resistance keeping goods securely in place Manufactured from nearly 100 recycled material each sheet is also 100 recyclable

Beyond the sale Rehrig can help you develop a customized re-use or buy-back program further lowering your average cost per trip

Phone (800) 546-4993 Email inforehrigpacificcom Web wwwrehrigpacificcom

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WAREHOUSESDCS

Industrial real estate market making progress challenges remain

mmh1010_newsindd 13 101310 1049 AM

14 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

ldquoWe are also concerned about seasonality with the holiday season coming uprdquo said Meyer ldquoThe indica-tions we are getting are that we may not see as much preparation for that as we hoped A lot of retailers are saying they are restocked and if consumer confi dence is going down they are not going to build up inventories And for larger big box companies they will see declining values in rents but the availability of product for them to lease is diminishingrdquo

As a result Class A big box dis-tribution space is becoming more diffi cult to fi nd in this economy said Meyer But the build-to-suit market could come back for major retailers as evidenced by a new 1-million-square-foot DC space deal by Amazoncom in Harrisburg Pa and a 14-million-square-foot location in Phoenix

But for a mid-sized industrial building in the 100000-to-150000-square-foot range Class B-sized build-

ing Meyer said there are an infi nite number of these on the market

Looking ahead Meyer said there will still be downward pressure on pric-

ing a double-digit vacancy rate and no increases in lease rates which he noted are actually weakening a little bit and tend to lag a recovery

Power AND CoNtrol

Introducing the latest innovations for incorporating Power AND Control into

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For over 60 years Itoh Denki has been the proven leader in the development and manufacture of superior motorized rollers and components This history provides you confidence in your 24V conveyor applications and designs a confidence based on the component integrity offered by the only sole source motor and control manufacturer in the industry

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LIFTrdquoBFL lifts are designed to move large loads ormultiple pallets betweenfloors These lifts willtravel from 8 feet to 18feet and have platformsizes ranging from 6rsquo x 8rsquo up to 8rsquo x 12rsquoThey are ideal for movinglarge loads 1-2 floors orup to high stages andmezzanines

1-800-843-3625wwwadvancel i f ts com

BFL AD MMH APRIL 92710 358 PM Page 1

CROWN EQUIPMENT Corp has quali-fi ed 20 of its electric models to operate with various fuel cells bringing the total of qualifi ed combinations of fuel cell packs and trucks to 29 In 2009 Crown (wwwcrowncom) was the fi rst lift truck manufacturer to introduce a fuel cell qualifi cation program

Eric Jensen Crownrsquos manager of new technology research and de-velopment told Modern that the companyrsquos fuel cell qualifi cation pro-gram duplicates its own testing and is conducted at a 25000-square-foot research facility near Dayton Ohio Through the testing process engi-

neers evaluate fuel cell performance and monitor whether issues develop that affect the truckrsquos operation

To qualify a fuel cell pack and truck combination Crownrsquos engineers review key performance metrics for a battery-powered truck such as traction plug-ging and lift and travel speeds Then they replace the battery with a fuel cell power pack and measure the same indicators Through modeling and ap-plication testing the research team de-termines design modifi cations needed to ensure the fuel cell-powered forklift matched standards to which the truck was designed

LIFT TRUCKS

Crown unveils 20 electric lift trucks to operate with fuel cells

mmh1010_newsindd 14 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 15

ldquoWersquove been steadfast in our posi-tion that deployment of a fuel cell forklift fl eet must be carefully evalu-ated and tested for appropriate use in a warehouserdquo said Jensen ldquoThis research-based approach means that our customers can confi dently know they have the right truck for their chosen fuel cell allowing them to meet their performance safety and

environmental sus-tainability goalsrdquo

Crown continues to work closely with fuel cell manufactur-ers and customers to qualify trucks as new fuel cell pack models are intro-duced ldquoForklifts are a key early market for fuel cellsrdquo said Lisa Callaghan Jerram senior market analyst for Fuel Cell Today a leading analyst

fi rm providing market-based research on the fuel cell industry ldquoBased on our market research we have found strong growth in this sector in the past three yearsrdquo

Because fuel cell powered electric forklifts give off exhaust in the form of moist warm air IC truck custom-ers are looking to this technology

so they donrsquot have to deal exhaust issues Jensen said Another advan-tage pointed out by Jensen is a fuel cell powered truckrsquos ability to effec-tively operate in a cold environment because they generate their own heat and the power doesnrsquot fall off like a traditional battery

While the upfront hardware cost of fuel cells is more expensive than a traditional battery Jensen pointed out the potential to capture savings in labor battery changes battery rooms and heating and venting With fuel cells he said a facility doesnrsquot need a battery room and all that goes in to running it properly Instead there is an ongoing savings associated to using fl oor space for production or other value-added operations

ldquoFuel cells have always been talked about fi ve years into the future but we have customers who are [currently] planning installations around this prod-uctrdquo said Jensen ldquoThe future is hererdquo

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review key performance metrics

mmh1010_newsindd 15 101310 1049 AM

lift truck TIPS

GraphicCaption

In the right application tuggers and carts can be a fast and efficient solution

Level the playing field

Football season is under-way and fans are hoping for breakout performances

from stars and rookies alike On the gridiron an overpowered player can be a distinct advan-tage In the warehouse how-ever too much power can lead to waste danger and sluggish performance For some corpo-rations this fact has prompted consideration of fork-free envi-ronments where versatile and custom-built carts and tuggers can do the work faster and more efficiently than their big-ger cousins

Disposing of expensive and powerful equipment in favor of carts may seem counter-intuitive but Jill Burrow marketing manager for Topper Industrial says certain warehouses might benefit greatly from the switch For operations requiring multiple trips between the same areas carts can cut travel time sig-nificantly According to Ed Brown president of Topper Industrial a tugger can pull as many as 13 carts In addi-tion says Brown carts and tuggers can be easier to use than many forklifts

ldquoA forklift costs five times as much but a forklift opera-tor also costs five times more than a tugger operatorrdquo says Brown ldquoAnyone can grab a tugger and gordquo

Once a forklift drops off a pallet in many cases a picker must bend to access product or arrange for the pallet to be lifted Carts on the other hand can be configured with swiveling or angled platforms to allow pickers fast and comfortable access to products Worker safety issues tied to forklifts that operate in tight areas such as poor visibility when driving in re-verse and dock mishaps can also be greatly reduced

ldquoCompanies looking at carts are looking at the cost of equipment and the cost of maintenance but theyrsquore also looking at safetyrdquo says Brown

In addition to ergonomics and safety a fork-free zone might help a warehouse reduce product loss and equip-ment damage Carts provide a secure cradle for moving product while some fork-borne loads are prone to top-pling And forklifts often 10 times as heavy as a tugger and cart setup have a way of proving their strength by leaving dings and dents on storage racks and other hap-less stationary objects

With carts and tuggers Brown says most companies see a return on investment within a year In football a first-round draft pick can cost millions over a multi-year contract before he produces the desired results For com-panies not looking to attempt such a Hail Mary tuggers could prove an efficient alternative

Josh Bond is a contributing editor to Modern and can be reached at turbobondgmailcom

16 O c t O b e r 2 0 1 0 Modern Materials Handling m m h c o m

lift truck TIPS

By Josh Bond Contributing Editor

MMH1010_LiftTruckTipsindd 16 101310 942 AM

MM100601Adsindd 3 6310 349 PMMMH1010_Adsindd 17 101210 1053 AM

18 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

Keith arntson vice president of distribution operations for

del Monte Foods

Four conveyor-topped vehicles ferry loads from an adjacent manufacturing plant

MMH1010_SystemRptDelMonteindd 18 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

bull Discover the newest robotics products and services bull See the latest robot-based solutions for picking and palletizing bull Understand how intelligent robots are revolutionizing processing

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Sponsoring companies include

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ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

Denso RoboticsElite EngineeringFANUC RoboticsFood EngineeringGenesis Systems GroupHartness InternationalKIva Systems

Modern Materials HandlingMotion Control RoboticsNational InstrumentsOmron Scientifi c Technologies IncRobotics TrendsWind RiverYaskawa Motoman Robotics

MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

chepcomsimplechoice

Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 13: Modern Materials Handling - October 2010

12 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

point the talent shortage isnrsquot limited just to the shop fl oor

Retrofi tting is a viable solution You know the old saying Every-thing old is new again Wegmanrsquos a Midwestern grocer and Rubber-maid both gave strong presenta-tions about how they replaced ag-ing ASRS cranes to breathe new life into their DCs Meanwhile Anheuser Busch gained new ef-fi ciencies in its Columbus Ohio facility by upgrading a warehouse control system

Everyone loves pallets Based in Iowa Green Line Armor is offering a heavy-duty hybrid woodplastic pallet for permanent pallet pools The 48- x 40-inch pallet has heavier stringers and more deck board coverage than a grocery pallet The lead boards on the top and the bottom of the palletmdashthose most likely to get damaged by a lift truckmdashare manufactured from heavy plastic The pallet has a passive RFID

tag that is used by Green Line Armor to identify the pallet and manage war-ranty services Active RFID tags were installed for John Deere the companyrsquos largest customer to track the location of work in process stored on the pallets between manufacturing processes Eric Renteria the companyrsquos president said the pallets which come with a 10-year warranty can be purchased or leased

in a pooling modelNew players are get-

ting into automation Kip Tygard whose company makes the Tygard Claw a lift truck attachment for mixed case palletizing is investing RampD money to develop an automated version of the Claw Thatrsquos not a big shock Tygard is an OEM But I also had conversations with two very large end users in the wholesale food distribu-

tion business that have designed their own automated systemsmdashone has built and implemented its own ASRS design for freezers for years the other has designed its own case picking application that it intends to put out for bid to the materials handling community Both say they may commercialize their solutions in the future

VERSATILITY MATTERSQuality Wildeck construction and versatility make the V-lifttrade the ultimate lifting solution

In todayrsquos lsquogreenrsquo building designs floor space is at a premium and moving up not out is definitely preferred Look no further than the V-Lifttrade from Wildeck ndash the industry leader in space optimization The single cylinder hydraulic system eliminates all moving hoses cables and chains Fewer components means easy installation reduced maintenance and longer service life To get more value out of your operation contact a Wildeck representative today

copyWildeck Inc 2010 Required safety gates and guarding removed for clarity

800-325-6939 | WWWWILDECKCOM

MEZZANINESCapacity Matters Efficiency Matters

LIFT SYSTEMSSafety MattersGUARDING PRODUCTS

able to make better decisionsmdashespecially in the case of the unexpected ldquoWhen a shipment is held up at the portrdquo says Prashant Bhatia director of solutions management at SAP ldquoit can trigger logic back to say that Irsquove got a problem I can no longer allocate that inventory on that particular shipment as I thought I couldrdquo

3 One database one system one supply chain In the last few years soft-ware providers have been pulling all of their products onto a single supply chain process platform ldquoItrsquos fairly newrdquo says Lamphier ldquoVarious components have been integrated into that supply chain process platform longer than others but actually moving our WMS onto it has been a more recent developmentmdashjust within the last quarter or twordquo

SAP uses its enterprise resource planning (ERP) system as the central repository of information of supply and demand as well as inventory for the entire supply chain And the modules all

talk to each other Transportation man-agement systems (TMS) in conjunction with the event management modules help optimize freight determine pick-up windows determine carriers keep track of in-transit times and create ASNs

That ASN not only gets sent back to the ERP for visibility but it also gets sent to the WMS where the sys-tem uses the information to plan labor equipment and resources at the receiv-ing dock When the physical product arrives logic within the WMS based on the receipt of goods determines matches against actual demand

Smarter speedier equipment With more retailers crossdocking

over 50 of their items at the case level to their stores equipment innovations have centered on conveyor sortation systems print and apply mechanisms and automatic identifi cation technolo-gies Here are three new equipment

advances1 Smaller gaps and self-regulat-

ing conveyors In the last year the sliding shoe sorter has undergone note-worthy transformations ldquoBy doing a par-allel divert we can now run the packages closer together and get a higher through-put on the same systemrdquo reports Ken Ruehrdanz manager for Dematicrsquos distri-bution and warehousing markets

The sliding shoes that used to physi-cally push the cartons off the sorter at an angle can now run those shoes in parallel enabling smaller gaps between cartonsmdashwhich were previously from 6 inches to 8 inchesmdashdown to 3 inches

With more dense traffi c on conveyors crossdock operators can run their con-veyors at a lower speed while still achiev-ing the same throughput Slower speeds equal less wear and tear decreased energy usage and less maintenance

Another conveyor breakthrough is automatic speed control ldquoThe whole

m m h c o m MODERN MATERIALS HANDLING A P R I L 2 0 1 0 49S

MMH100401sup_Crossdock_ID 49 482010 113620 AM

Leading customers are investing in software and automated

systems to improve business according to attendees of the

Supply Chain Reset conference

mmh1010_newsindd 12 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 13

THE INDUSTRIAL REAL ESTATEmarket is taking steps in the right direction according to a report recently issued by global real estate fi rm Jones Lang LaSalle (JLL wwwjoneslanglasallecom) which report-ed the national average vacancy rate for the North American industrial real estate sector fell from 106 in the fi rst quarter to 104 in the second quarter Despite the slight decline in vacancy the fragile economy still looms large due to declining con-sumer confi dence the drying up of economic stimulus funding and the potential threat of a double-dip recession the report noted

ldquoWe have seen a positive absorp-tion in the vacancy rate in the second quarter but we are very concerned

going forwardrdquo Craig Meyer managing director and leader of JLLrsquos Logistics and Industrial Services Group told Modern ldquoAny kind of sustained demand-driven component in the industrial real estate market is going to be driven by jobs We are just not seeing any of that It is going to be a long slow recoveryrdquo

Looking at base indicators like the Institute of Supply Managementrsquos Manufacturing Index Consumer Confi dence data and industrial real estate vacancy and absorption rates there does not appear to be what Meyer labeled as a strong indication of a positive upswing on the horizon

The report says that a need to restock inventories that were running at 50-year lows resulted in large com-panies strategically capturing high

quality logistics space at cyclically low rates And with slow levels of leasing activity and sparse construc-tion industrial real estate optionsmdashespecially in the Class A large block sectormdashare limited in some markets

And the swift correction in invento-ries during the second half of 2009 and fi rst quarter of 2010 has left inventory levels lean and ready for expansion provided sales rebound in the coming months Should this occur it could lead to increased industrial and logistics real estate leasing activity

The report also pointed out that the initial recovery in the economy was largely driven by improvements in the manufacturing sector and cyclical adjustments in inventories But with the recovery now becoming more broad-based the recent slowdown of inven-tory building could have more of an impact on the industrial property sector than the offi ce sector the report noted

Date 090910 Client Rehrig Pacifi c Job 08312010 File Name 0831_RPC_SlipSheet_Ad_MMH_Oct10 Round

Account Director Niki Phan Designer Revised By ov Editor Production ov

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Publication(s) TBD Run Date(s) TBD

Approved By

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Available in standard or custom sizes with a variety of surface textures and embossed patterns Rehrig Slip Sheets provide superior slide resistance keeping goods securely in place Manufactured from nearly 100 recycled material each sheet is also 100 recyclable

Beyond the sale Rehrig can help you develop a customized re-use or buy-back program further lowering your average cost per trip

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Industrial real estate market making progress challenges remain

mmh1010_newsindd 13 101310 1049 AM

14 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

ldquoWe are also concerned about seasonality with the holiday season coming uprdquo said Meyer ldquoThe indica-tions we are getting are that we may not see as much preparation for that as we hoped A lot of retailers are saying they are restocked and if consumer confi dence is going down they are not going to build up inventories And for larger big box companies they will see declining values in rents but the availability of product for them to lease is diminishingrdquo

As a result Class A big box dis-tribution space is becoming more diffi cult to fi nd in this economy said Meyer But the build-to-suit market could come back for major retailers as evidenced by a new 1-million-square-foot DC space deal by Amazoncom in Harrisburg Pa and a 14-million-square-foot location in Phoenix

But for a mid-sized industrial building in the 100000-to-150000-square-foot range Class B-sized build-

ing Meyer said there are an infi nite number of these on the market

Looking ahead Meyer said there will still be downward pressure on pric-

ing a double-digit vacancy rate and no increases in lease rates which he noted are actually weakening a little bit and tend to lag a recovery

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BFL AD MMH APRIL 92710 358 PM Page 1

CROWN EQUIPMENT Corp has quali-fi ed 20 of its electric models to operate with various fuel cells bringing the total of qualifi ed combinations of fuel cell packs and trucks to 29 In 2009 Crown (wwwcrowncom) was the fi rst lift truck manufacturer to introduce a fuel cell qualifi cation program

Eric Jensen Crownrsquos manager of new technology research and de-velopment told Modern that the companyrsquos fuel cell qualifi cation pro-gram duplicates its own testing and is conducted at a 25000-square-foot research facility near Dayton Ohio Through the testing process engi-

neers evaluate fuel cell performance and monitor whether issues develop that affect the truckrsquos operation

To qualify a fuel cell pack and truck combination Crownrsquos engineers review key performance metrics for a battery-powered truck such as traction plug-ging and lift and travel speeds Then they replace the battery with a fuel cell power pack and measure the same indicators Through modeling and ap-plication testing the research team de-termines design modifi cations needed to ensure the fuel cell-powered forklift matched standards to which the truck was designed

LIFT TRUCKS

Crown unveils 20 electric lift trucks to operate with fuel cells

mmh1010_newsindd 14 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 15

ldquoWersquove been steadfast in our posi-tion that deployment of a fuel cell forklift fl eet must be carefully evalu-ated and tested for appropriate use in a warehouserdquo said Jensen ldquoThis research-based approach means that our customers can confi dently know they have the right truck for their chosen fuel cell allowing them to meet their performance safety and

environmental sus-tainability goalsrdquo

Crown continues to work closely with fuel cell manufactur-ers and customers to qualify trucks as new fuel cell pack models are intro-duced ldquoForklifts are a key early market for fuel cellsrdquo said Lisa Callaghan Jerram senior market analyst for Fuel Cell Today a leading analyst

fi rm providing market-based research on the fuel cell industry ldquoBased on our market research we have found strong growth in this sector in the past three yearsrdquo

Because fuel cell powered electric forklifts give off exhaust in the form of moist warm air IC truck custom-ers are looking to this technology

so they donrsquot have to deal exhaust issues Jensen said Another advan-tage pointed out by Jensen is a fuel cell powered truckrsquos ability to effec-tively operate in a cold environment because they generate their own heat and the power doesnrsquot fall off like a traditional battery

While the upfront hardware cost of fuel cells is more expensive than a traditional battery Jensen pointed out the potential to capture savings in labor battery changes battery rooms and heating and venting With fuel cells he said a facility doesnrsquot need a battery room and all that goes in to running it properly Instead there is an ongoing savings associated to using fl oor space for production or other value-added operations

ldquoFuel cells have always been talked about fi ve years into the future but we have customers who are [currently] planning installations around this prod-uctrdquo said Jensen ldquoThe future is hererdquo

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To qualify a fuel cell pack and truck combination engineers

review key performance metrics

mmh1010_newsindd 15 101310 1049 AM

lift truck TIPS

GraphicCaption

In the right application tuggers and carts can be a fast and efficient solution

Level the playing field

Football season is under-way and fans are hoping for breakout performances

from stars and rookies alike On the gridiron an overpowered player can be a distinct advan-tage In the warehouse how-ever too much power can lead to waste danger and sluggish performance For some corpo-rations this fact has prompted consideration of fork-free envi-ronments where versatile and custom-built carts and tuggers can do the work faster and more efficiently than their big-ger cousins

Disposing of expensive and powerful equipment in favor of carts may seem counter-intuitive but Jill Burrow marketing manager for Topper Industrial says certain warehouses might benefit greatly from the switch For operations requiring multiple trips between the same areas carts can cut travel time sig-nificantly According to Ed Brown president of Topper Industrial a tugger can pull as many as 13 carts In addi-tion says Brown carts and tuggers can be easier to use than many forklifts

ldquoA forklift costs five times as much but a forklift opera-tor also costs five times more than a tugger operatorrdquo says Brown ldquoAnyone can grab a tugger and gordquo

Once a forklift drops off a pallet in many cases a picker must bend to access product or arrange for the pallet to be lifted Carts on the other hand can be configured with swiveling or angled platforms to allow pickers fast and comfortable access to products Worker safety issues tied to forklifts that operate in tight areas such as poor visibility when driving in re-verse and dock mishaps can also be greatly reduced

ldquoCompanies looking at carts are looking at the cost of equipment and the cost of maintenance but theyrsquore also looking at safetyrdquo says Brown

In addition to ergonomics and safety a fork-free zone might help a warehouse reduce product loss and equip-ment damage Carts provide a secure cradle for moving product while some fork-borne loads are prone to top-pling And forklifts often 10 times as heavy as a tugger and cart setup have a way of proving their strength by leaving dings and dents on storage racks and other hap-less stationary objects

With carts and tuggers Brown says most companies see a return on investment within a year In football a first-round draft pick can cost millions over a multi-year contract before he produces the desired results For com-panies not looking to attempt such a Hail Mary tuggers could prove an efficient alternative

Josh Bond is a contributing editor to Modern and can be reached at turbobondgmailcom

16 O c t O b e r 2 0 1 0 Modern Materials Handling m m h c o m

lift truck TIPS

By Josh Bond Contributing Editor

MMH1010_LiftTruckTipsindd 16 101310 942 AM

MM100601Adsindd 3 6310 349 PMMMH1010_Adsindd 17 101210 1053 AM

18 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

Keith arntson vice president of distribution operations for

del Monte Foods

Four conveyor-topped vehicles ferry loads from an adjacent manufacturing plant

MMH1010_SystemRptDelMonteindd 18 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

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Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

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Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

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From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

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mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

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Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

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MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

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As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

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  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 14: Modern Materials Handling - October 2010

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 13

THE INDUSTRIAL REAL ESTATEmarket is taking steps in the right direction according to a report recently issued by global real estate fi rm Jones Lang LaSalle (JLL wwwjoneslanglasallecom) which report-ed the national average vacancy rate for the North American industrial real estate sector fell from 106 in the fi rst quarter to 104 in the second quarter Despite the slight decline in vacancy the fragile economy still looms large due to declining con-sumer confi dence the drying up of economic stimulus funding and the potential threat of a double-dip recession the report noted

ldquoWe have seen a positive absorp-tion in the vacancy rate in the second quarter but we are very concerned

going forwardrdquo Craig Meyer managing director and leader of JLLrsquos Logistics and Industrial Services Group told Modern ldquoAny kind of sustained demand-driven component in the industrial real estate market is going to be driven by jobs We are just not seeing any of that It is going to be a long slow recoveryrdquo

Looking at base indicators like the Institute of Supply Managementrsquos Manufacturing Index Consumer Confi dence data and industrial real estate vacancy and absorption rates there does not appear to be what Meyer labeled as a strong indication of a positive upswing on the horizon

The report says that a need to restock inventories that were running at 50-year lows resulted in large com-panies strategically capturing high

quality logistics space at cyclically low rates And with slow levels of leasing activity and sparse construc-tion industrial real estate optionsmdashespecially in the Class A large block sectormdashare limited in some markets

And the swift correction in invento-ries during the second half of 2009 and fi rst quarter of 2010 has left inventory levels lean and ready for expansion provided sales rebound in the coming months Should this occur it could lead to increased industrial and logistics real estate leasing activity

The report also pointed out that the initial recovery in the economy was largely driven by improvements in the manufacturing sector and cyclical adjustments in inventories But with the recovery now becoming more broad-based the recent slowdown of inven-tory building could have more of an impact on the industrial property sector than the offi ce sector the report noted

Date 090910 Client Rehrig Pacifi c Job 08312010 File Name 0831_RPC_SlipSheet_Ad_MMH_Oct10 Round

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Available in standard or custom sizes with a variety of surface textures and embossed patterns Rehrig Slip Sheets provide superior slide resistance keeping goods securely in place Manufactured from nearly 100 recycled material each sheet is also 100 recyclable

Beyond the sale Rehrig can help you develop a customized re-use or buy-back program further lowering your average cost per trip

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WAREHOUSESDCS

Industrial real estate market making progress challenges remain

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14 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

ldquoWe are also concerned about seasonality with the holiday season coming uprdquo said Meyer ldquoThe indica-tions we are getting are that we may not see as much preparation for that as we hoped A lot of retailers are saying they are restocked and if consumer confi dence is going down they are not going to build up inventories And for larger big box companies they will see declining values in rents but the availability of product for them to lease is diminishingrdquo

As a result Class A big box dis-tribution space is becoming more diffi cult to fi nd in this economy said Meyer But the build-to-suit market could come back for major retailers as evidenced by a new 1-million-square-foot DC space deal by Amazoncom in Harrisburg Pa and a 14-million-square-foot location in Phoenix

But for a mid-sized industrial building in the 100000-to-150000-square-foot range Class B-sized build-

ing Meyer said there are an infi nite number of these on the market

Looking ahead Meyer said there will still be downward pressure on pric-

ing a double-digit vacancy rate and no increases in lease rates which he noted are actually weakening a little bit and tend to lag a recovery

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BFL AD MMH APRIL 92710 358 PM Page 1

CROWN EQUIPMENT Corp has quali-fi ed 20 of its electric models to operate with various fuel cells bringing the total of qualifi ed combinations of fuel cell packs and trucks to 29 In 2009 Crown (wwwcrowncom) was the fi rst lift truck manufacturer to introduce a fuel cell qualifi cation program

Eric Jensen Crownrsquos manager of new technology research and de-velopment told Modern that the companyrsquos fuel cell qualifi cation pro-gram duplicates its own testing and is conducted at a 25000-square-foot research facility near Dayton Ohio Through the testing process engi-

neers evaluate fuel cell performance and monitor whether issues develop that affect the truckrsquos operation

To qualify a fuel cell pack and truck combination Crownrsquos engineers review key performance metrics for a battery-powered truck such as traction plug-ging and lift and travel speeds Then they replace the battery with a fuel cell power pack and measure the same indicators Through modeling and ap-plication testing the research team de-termines design modifi cations needed to ensure the fuel cell-powered forklift matched standards to which the truck was designed

LIFT TRUCKS

Crown unveils 20 electric lift trucks to operate with fuel cells

mmh1010_newsindd 14 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 15

ldquoWersquove been steadfast in our posi-tion that deployment of a fuel cell forklift fl eet must be carefully evalu-ated and tested for appropriate use in a warehouserdquo said Jensen ldquoThis research-based approach means that our customers can confi dently know they have the right truck for their chosen fuel cell allowing them to meet their performance safety and

environmental sus-tainability goalsrdquo

Crown continues to work closely with fuel cell manufactur-ers and customers to qualify trucks as new fuel cell pack models are intro-duced ldquoForklifts are a key early market for fuel cellsrdquo said Lisa Callaghan Jerram senior market analyst for Fuel Cell Today a leading analyst

fi rm providing market-based research on the fuel cell industry ldquoBased on our market research we have found strong growth in this sector in the past three yearsrdquo

Because fuel cell powered electric forklifts give off exhaust in the form of moist warm air IC truck custom-ers are looking to this technology

so they donrsquot have to deal exhaust issues Jensen said Another advan-tage pointed out by Jensen is a fuel cell powered truckrsquos ability to effec-tively operate in a cold environment because they generate their own heat and the power doesnrsquot fall off like a traditional battery

While the upfront hardware cost of fuel cells is more expensive than a traditional battery Jensen pointed out the potential to capture savings in labor battery changes battery rooms and heating and venting With fuel cells he said a facility doesnrsquot need a battery room and all that goes in to running it properly Instead there is an ongoing savings associated to using fl oor space for production or other value-added operations

ldquoFuel cells have always been talked about fi ve years into the future but we have customers who are [currently] planning installations around this prod-uctrdquo said Jensen ldquoThe future is hererdquo

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To qualify a fuel cell pack and truck combination engineers

review key performance metrics

mmh1010_newsindd 15 101310 1049 AM

lift truck TIPS

GraphicCaption

In the right application tuggers and carts can be a fast and efficient solution

Level the playing field

Football season is under-way and fans are hoping for breakout performances

from stars and rookies alike On the gridiron an overpowered player can be a distinct advan-tage In the warehouse how-ever too much power can lead to waste danger and sluggish performance For some corpo-rations this fact has prompted consideration of fork-free envi-ronments where versatile and custom-built carts and tuggers can do the work faster and more efficiently than their big-ger cousins

Disposing of expensive and powerful equipment in favor of carts may seem counter-intuitive but Jill Burrow marketing manager for Topper Industrial says certain warehouses might benefit greatly from the switch For operations requiring multiple trips between the same areas carts can cut travel time sig-nificantly According to Ed Brown president of Topper Industrial a tugger can pull as many as 13 carts In addi-tion says Brown carts and tuggers can be easier to use than many forklifts

ldquoA forklift costs five times as much but a forklift opera-tor also costs five times more than a tugger operatorrdquo says Brown ldquoAnyone can grab a tugger and gordquo

Once a forklift drops off a pallet in many cases a picker must bend to access product or arrange for the pallet to be lifted Carts on the other hand can be configured with swiveling or angled platforms to allow pickers fast and comfortable access to products Worker safety issues tied to forklifts that operate in tight areas such as poor visibility when driving in re-verse and dock mishaps can also be greatly reduced

ldquoCompanies looking at carts are looking at the cost of equipment and the cost of maintenance but theyrsquore also looking at safetyrdquo says Brown

In addition to ergonomics and safety a fork-free zone might help a warehouse reduce product loss and equip-ment damage Carts provide a secure cradle for moving product while some fork-borne loads are prone to top-pling And forklifts often 10 times as heavy as a tugger and cart setup have a way of proving their strength by leaving dings and dents on storage racks and other hap-less stationary objects

With carts and tuggers Brown says most companies see a return on investment within a year In football a first-round draft pick can cost millions over a multi-year contract before he produces the desired results For com-panies not looking to attempt such a Hail Mary tuggers could prove an efficient alternative

Josh Bond is a contributing editor to Modern and can be reached at turbobondgmailcom

16 O c t O b e r 2 0 1 0 Modern Materials Handling m m h c o m

lift truck TIPS

By Josh Bond Contributing Editor

MMH1010_LiftTruckTipsindd 16 101310 942 AM

MM100601Adsindd 3 6310 349 PMMMH1010_Adsindd 17 101210 1053 AM

18 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

Keith arntson vice president of distribution operations for

del Monte Foods

Four conveyor-topped vehicles ferry loads from an adjacent manufacturing plant

MMH1010_SystemRptDelMonteindd 18 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

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ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

Denso RoboticsElite EngineeringFANUC RoboticsFood EngineeringGenesis Systems GroupHartness InternationalKIva Systems

Modern Materials HandlingMotion Control RoboticsNational InstrumentsOmron Scientifi c Technologies IncRobotics TrendsWind RiverYaskawa Motoman Robotics

MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

chepcomsimplechoice

Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

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Find us on

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MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

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SUPERIOR BANDS

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8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

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NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 15: Modern Materials Handling - October 2010

14 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING m m h c o m

ldquoWe are also concerned about seasonality with the holiday season coming uprdquo said Meyer ldquoThe indica-tions we are getting are that we may not see as much preparation for that as we hoped A lot of retailers are saying they are restocked and if consumer confi dence is going down they are not going to build up inventories And for larger big box companies they will see declining values in rents but the availability of product for them to lease is diminishingrdquo

As a result Class A big box dis-tribution space is becoming more diffi cult to fi nd in this economy said Meyer But the build-to-suit market could come back for major retailers as evidenced by a new 1-million-square-foot DC space deal by Amazoncom in Harrisburg Pa and a 14-million-square-foot location in Phoenix

But for a mid-sized industrial building in the 100000-to-150000-square-foot range Class B-sized build-

ing Meyer said there are an infi nite number of these on the market

Looking ahead Meyer said there will still be downward pressure on pric-

ing a double-digit vacancy rate and no increases in lease rates which he noted are actually weakening a little bit and tend to lag a recovery

Power AND CoNtrol

Introducing the latest innovations for incorporating Power AND Control into

your 24 VDC conveyor system

For over 60 years Itoh Denki has been the proven leader in the development and manufacture of superior motorized rollers and components This history provides you confidence in your 24V conveyor applications and designs a confidence based on the component integrity offered by the only sole source motor and control manufacturer in the industry

135 Stewart Road Hanover Industrial Estates bull Hanover Township PA 18706-1462

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Intelligent solutions yoursquod expect from Itoh Denki Intelligent solutions yoursquod expect from Itoh Denki

BFL SERIESldquoBIG FRIGGIN

LIFTrdquoBFL lifts are designed to move large loads ormultiple pallets betweenfloors These lifts willtravel from 8 feet to 18feet and have platformsizes ranging from 6rsquo x 8rsquo up to 8rsquo x 12rsquoThey are ideal for movinglarge loads 1-2 floors orup to high stages andmezzanines

1-800-843-3625wwwadvancel i f ts com

BFL AD MMH APRIL 92710 358 PM Page 1

CROWN EQUIPMENT Corp has quali-fi ed 20 of its electric models to operate with various fuel cells bringing the total of qualifi ed combinations of fuel cell packs and trucks to 29 In 2009 Crown (wwwcrowncom) was the fi rst lift truck manufacturer to introduce a fuel cell qualifi cation program

Eric Jensen Crownrsquos manager of new technology research and de-velopment told Modern that the companyrsquos fuel cell qualifi cation pro-gram duplicates its own testing and is conducted at a 25000-square-foot research facility near Dayton Ohio Through the testing process engi-

neers evaluate fuel cell performance and monitor whether issues develop that affect the truckrsquos operation

To qualify a fuel cell pack and truck combination Crownrsquos engineers review key performance metrics for a battery-powered truck such as traction plug-ging and lift and travel speeds Then they replace the battery with a fuel cell power pack and measure the same indicators Through modeling and ap-plication testing the research team de-termines design modifi cations needed to ensure the fuel cell-powered forklift matched standards to which the truck was designed

LIFT TRUCKS

Crown unveils 20 electric lift trucks to operate with fuel cells

mmh1010_newsindd 14 101310 1049 AM

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 15

ldquoWersquove been steadfast in our posi-tion that deployment of a fuel cell forklift fl eet must be carefully evalu-ated and tested for appropriate use in a warehouserdquo said Jensen ldquoThis research-based approach means that our customers can confi dently know they have the right truck for their chosen fuel cell allowing them to meet their performance safety and

environmental sus-tainability goalsrdquo

Crown continues to work closely with fuel cell manufactur-ers and customers to qualify trucks as new fuel cell pack models are intro-duced ldquoForklifts are a key early market for fuel cellsrdquo said Lisa Callaghan Jerram senior market analyst for Fuel Cell Today a leading analyst

fi rm providing market-based research on the fuel cell industry ldquoBased on our market research we have found strong growth in this sector in the past three yearsrdquo

Because fuel cell powered electric forklifts give off exhaust in the form of moist warm air IC truck custom-ers are looking to this technology

so they donrsquot have to deal exhaust issues Jensen said Another advan-tage pointed out by Jensen is a fuel cell powered truckrsquos ability to effec-tively operate in a cold environment because they generate their own heat and the power doesnrsquot fall off like a traditional battery

While the upfront hardware cost of fuel cells is more expensive than a traditional battery Jensen pointed out the potential to capture savings in labor battery changes battery rooms and heating and venting With fuel cells he said a facility doesnrsquot need a battery room and all that goes in to running it properly Instead there is an ongoing savings associated to using fl oor space for production or other value-added operations

ldquoFuel cells have always been talked about fi ve years into the future but we have customers who are [currently] planning installations around this prod-uctrdquo said Jensen ldquoThe future is hererdquo

Buildings available up to

300 wide Low in cost per

square footNatural daytime

lightingEasy to relocate

ExpandableLittle or no

property taxes

Call one of our ClearSpan Specialists at 18666431010 or visit us at wwwClearSpancom Mention code CST1109

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on Fabric StructureS amp GreenHouSeS

Subject to credit approval

To qualify a fuel cell pack and truck combination engineers

review key performance metrics

mmh1010_newsindd 15 101310 1049 AM

lift truck TIPS

GraphicCaption

In the right application tuggers and carts can be a fast and efficient solution

Level the playing field

Football season is under-way and fans are hoping for breakout performances

from stars and rookies alike On the gridiron an overpowered player can be a distinct advan-tage In the warehouse how-ever too much power can lead to waste danger and sluggish performance For some corpo-rations this fact has prompted consideration of fork-free envi-ronments where versatile and custom-built carts and tuggers can do the work faster and more efficiently than their big-ger cousins

Disposing of expensive and powerful equipment in favor of carts may seem counter-intuitive but Jill Burrow marketing manager for Topper Industrial says certain warehouses might benefit greatly from the switch For operations requiring multiple trips between the same areas carts can cut travel time sig-nificantly According to Ed Brown president of Topper Industrial a tugger can pull as many as 13 carts In addi-tion says Brown carts and tuggers can be easier to use than many forklifts

ldquoA forklift costs five times as much but a forklift opera-tor also costs five times more than a tugger operatorrdquo says Brown ldquoAnyone can grab a tugger and gordquo

Once a forklift drops off a pallet in many cases a picker must bend to access product or arrange for the pallet to be lifted Carts on the other hand can be configured with swiveling or angled platforms to allow pickers fast and comfortable access to products Worker safety issues tied to forklifts that operate in tight areas such as poor visibility when driving in re-verse and dock mishaps can also be greatly reduced

ldquoCompanies looking at carts are looking at the cost of equipment and the cost of maintenance but theyrsquore also looking at safetyrdquo says Brown

In addition to ergonomics and safety a fork-free zone might help a warehouse reduce product loss and equip-ment damage Carts provide a secure cradle for moving product while some fork-borne loads are prone to top-pling And forklifts often 10 times as heavy as a tugger and cart setup have a way of proving their strength by leaving dings and dents on storage racks and other hap-less stationary objects

With carts and tuggers Brown says most companies see a return on investment within a year In football a first-round draft pick can cost millions over a multi-year contract before he produces the desired results For com-panies not looking to attempt such a Hail Mary tuggers could prove an efficient alternative

Josh Bond is a contributing editor to Modern and can be reached at turbobondgmailcom

16 O c t O b e r 2 0 1 0 Modern Materials Handling m m h c o m

lift truck TIPS

By Josh Bond Contributing Editor

MMH1010_LiftTruckTipsindd 16 101310 942 AM

MM100601Adsindd 3 6310 349 PMMMH1010_Adsindd 17 101210 1053 AM

18 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

Keith arntson vice president of distribution operations for

del Monte Foods

Four conveyor-topped vehicles ferry loads from an adjacent manufacturing plant

MMH1010_SystemRptDelMonteindd 18 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

bull Discover the newest robotics products and services bull See the latest robot-based solutions for picking and palletizing bull Understand how intelligent robots are revolutionizing processing

packaging plant operations and material handling bull Learn about robotics solutions that will increase your bottom line

Sponsoring companies include

Register TodaymdashItrsquos FREE Go to robovirtualeventscom

ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

Denso RoboticsElite EngineeringFANUC RoboticsFood EngineeringGenesis Systems GroupHartness InternationalKIva Systems

Modern Materials HandlingMotion Control RoboticsNational InstrumentsOmron Scientifi c Technologies IncRobotics TrendsWind RiverYaskawa Motoman Robotics

MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 16: Modern Materials Handling - October 2010

m m h c o m MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 15

ldquoWersquove been steadfast in our posi-tion that deployment of a fuel cell forklift fl eet must be carefully evalu-ated and tested for appropriate use in a warehouserdquo said Jensen ldquoThis research-based approach means that our customers can confi dently know they have the right truck for their chosen fuel cell allowing them to meet their performance safety and

environmental sus-tainability goalsrdquo

Crown continues to work closely with fuel cell manufactur-ers and customers to qualify trucks as new fuel cell pack models are intro-duced ldquoForklifts are a key early market for fuel cellsrdquo said Lisa Callaghan Jerram senior market analyst for Fuel Cell Today a leading analyst

fi rm providing market-based research on the fuel cell industry ldquoBased on our market research we have found strong growth in this sector in the past three yearsrdquo

Because fuel cell powered electric forklifts give off exhaust in the form of moist warm air IC truck custom-ers are looking to this technology

so they donrsquot have to deal exhaust issues Jensen said Another advan-tage pointed out by Jensen is a fuel cell powered truckrsquos ability to effec-tively operate in a cold environment because they generate their own heat and the power doesnrsquot fall off like a traditional battery

While the upfront hardware cost of fuel cells is more expensive than a traditional battery Jensen pointed out the potential to capture savings in labor battery changes battery rooms and heating and venting With fuel cells he said a facility doesnrsquot need a battery room and all that goes in to running it properly Instead there is an ongoing savings associated to using fl oor space for production or other value-added operations

ldquoFuel cells have always been talked about fi ve years into the future but we have customers who are [currently] planning installations around this prod-uctrdquo said Jensen ldquoThe future is hererdquo

Buildings available up to

300 wide Low in cost per

square footNatural daytime

lightingEasy to relocate

ExpandableLittle or no

property taxes

Call one of our ClearSpan Specialists at 18666431010 or visit us at wwwClearSpancom Mention code CST1109

Sustainable Design-Build Solutions

Flexible Finance SolutionStermS up to 10 yearS rateS aS low aS 499 aS little aS 10 down

on Fabric StructureS amp GreenHouSeS

Subject to credit approval

To qualify a fuel cell pack and truck combination engineers

review key performance metrics

mmh1010_newsindd 15 101310 1049 AM

lift truck TIPS

GraphicCaption

In the right application tuggers and carts can be a fast and efficient solution

Level the playing field

Football season is under-way and fans are hoping for breakout performances

from stars and rookies alike On the gridiron an overpowered player can be a distinct advan-tage In the warehouse how-ever too much power can lead to waste danger and sluggish performance For some corpo-rations this fact has prompted consideration of fork-free envi-ronments where versatile and custom-built carts and tuggers can do the work faster and more efficiently than their big-ger cousins

Disposing of expensive and powerful equipment in favor of carts may seem counter-intuitive but Jill Burrow marketing manager for Topper Industrial says certain warehouses might benefit greatly from the switch For operations requiring multiple trips between the same areas carts can cut travel time sig-nificantly According to Ed Brown president of Topper Industrial a tugger can pull as many as 13 carts In addi-tion says Brown carts and tuggers can be easier to use than many forklifts

ldquoA forklift costs five times as much but a forklift opera-tor also costs five times more than a tugger operatorrdquo says Brown ldquoAnyone can grab a tugger and gordquo

Once a forklift drops off a pallet in many cases a picker must bend to access product or arrange for the pallet to be lifted Carts on the other hand can be configured with swiveling or angled platforms to allow pickers fast and comfortable access to products Worker safety issues tied to forklifts that operate in tight areas such as poor visibility when driving in re-verse and dock mishaps can also be greatly reduced

ldquoCompanies looking at carts are looking at the cost of equipment and the cost of maintenance but theyrsquore also looking at safetyrdquo says Brown

In addition to ergonomics and safety a fork-free zone might help a warehouse reduce product loss and equip-ment damage Carts provide a secure cradle for moving product while some fork-borne loads are prone to top-pling And forklifts often 10 times as heavy as a tugger and cart setup have a way of proving their strength by leaving dings and dents on storage racks and other hap-less stationary objects

With carts and tuggers Brown says most companies see a return on investment within a year In football a first-round draft pick can cost millions over a multi-year contract before he produces the desired results For com-panies not looking to attempt such a Hail Mary tuggers could prove an efficient alternative

Josh Bond is a contributing editor to Modern and can be reached at turbobondgmailcom

16 O c t O b e r 2 0 1 0 Modern Materials Handling m m h c o m

lift truck TIPS

By Josh Bond Contributing Editor

MMH1010_LiftTruckTipsindd 16 101310 942 AM

MM100601Adsindd 3 6310 349 PMMMH1010_Adsindd 17 101210 1053 AM

18 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

Keith arntson vice president of distribution operations for

del Monte Foods

Four conveyor-topped vehicles ferry loads from an adjacent manufacturing plant

MMH1010_SystemRptDelMonteindd 18 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

bull Discover the newest robotics products and services bull See the latest robot-based solutions for picking and palletizing bull Understand how intelligent robots are revolutionizing processing

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Sponsoring companies include

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ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

Denso RoboticsElite EngineeringFANUC RoboticsFood EngineeringGenesis Systems GroupHartness InternationalKIva Systems

Modern Materials HandlingMotion Control RoboticsNational InstrumentsOmron Scientifi c Technologies IncRobotics TrendsWind RiverYaskawa Motoman Robotics

MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

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Holster YourSide Arm

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Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

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C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 17: Modern Materials Handling - October 2010

lift truck TIPS

GraphicCaption

In the right application tuggers and carts can be a fast and efficient solution

Level the playing field

Football season is under-way and fans are hoping for breakout performances

from stars and rookies alike On the gridiron an overpowered player can be a distinct advan-tage In the warehouse how-ever too much power can lead to waste danger and sluggish performance For some corpo-rations this fact has prompted consideration of fork-free envi-ronments where versatile and custom-built carts and tuggers can do the work faster and more efficiently than their big-ger cousins

Disposing of expensive and powerful equipment in favor of carts may seem counter-intuitive but Jill Burrow marketing manager for Topper Industrial says certain warehouses might benefit greatly from the switch For operations requiring multiple trips between the same areas carts can cut travel time sig-nificantly According to Ed Brown president of Topper Industrial a tugger can pull as many as 13 carts In addi-tion says Brown carts and tuggers can be easier to use than many forklifts

ldquoA forklift costs five times as much but a forklift opera-tor also costs five times more than a tugger operatorrdquo says Brown ldquoAnyone can grab a tugger and gordquo

Once a forklift drops off a pallet in many cases a picker must bend to access product or arrange for the pallet to be lifted Carts on the other hand can be configured with swiveling or angled platforms to allow pickers fast and comfortable access to products Worker safety issues tied to forklifts that operate in tight areas such as poor visibility when driving in re-verse and dock mishaps can also be greatly reduced

ldquoCompanies looking at carts are looking at the cost of equipment and the cost of maintenance but theyrsquore also looking at safetyrdquo says Brown

In addition to ergonomics and safety a fork-free zone might help a warehouse reduce product loss and equip-ment damage Carts provide a secure cradle for moving product while some fork-borne loads are prone to top-pling And forklifts often 10 times as heavy as a tugger and cart setup have a way of proving their strength by leaving dings and dents on storage racks and other hap-less stationary objects

With carts and tuggers Brown says most companies see a return on investment within a year In football a first-round draft pick can cost millions over a multi-year contract before he produces the desired results For com-panies not looking to attempt such a Hail Mary tuggers could prove an efficient alternative

Josh Bond is a contributing editor to Modern and can be reached at turbobondgmailcom

16 O c t O b e r 2 0 1 0 Modern Materials Handling m m h c o m

lift truck TIPS

By Josh Bond Contributing Editor

MMH1010_LiftTruckTipsindd 16 101310 942 AM

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18 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

Keith arntson vice president of distribution operations for

del Monte Foods

Four conveyor-topped vehicles ferry loads from an adjacent manufacturing plant

MMH1010_SystemRptDelMonteindd 18 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

bull Discover the newest robotics products and services bull See the latest robot-based solutions for picking and palletizing bull Understand how intelligent robots are revolutionizing processing

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Sponsoring companies include

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ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

Denso RoboticsElite EngineeringFANUC RoboticsFood EngineeringGenesis Systems GroupHartness InternationalKIva Systems

Modern Materials HandlingMotion Control RoboticsNational InstrumentsOmron Scientifi c Technologies IncRobotics TrendsWind RiverYaskawa Motoman Robotics

MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

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Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

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2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

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C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

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  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 18: Modern Materials Handling - October 2010

MM100601Adsindd 3 6310 349 PMMMH1010_Adsindd 17 101210 1053 AM

18 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

Keith arntson vice president of distribution operations for

del Monte Foods

Four conveyor-topped vehicles ferry loads from an adjacent manufacturing plant

MMH1010_SystemRptDelMonteindd 18 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

bull Discover the newest robotics products and services bull See the latest robot-based solutions for picking and palletizing bull Understand how intelligent robots are revolutionizing processing

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Sponsoring companies include

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ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

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MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

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Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

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2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

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C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

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  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 19: Modern Materials Handling - October 2010

18 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

Keith arntson vice president of distribution operations for

del Monte Foods

Four conveyor-topped vehicles ferry loads from an adjacent manufacturing plant

MMH1010_SystemRptDelMonteindd 18 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

bull Discover the newest robotics products and services bull See the latest robot-based solutions for picking and palletizing bull Understand how intelligent robots are revolutionizing processing

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Sponsoring companies include

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ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

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MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

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Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

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C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

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  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 20: Modern Materials Handling - October 2010

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 19

modern system report

PH

OTO

GR

AP

HY

BLA

INE

FIS

HE

R

ABy Bob trebilcock Executive Editor

del Monte Foodsrsquo new topeka dC brings laser-guided

agVs from manufacturing into distribution the result is

a best-in-class materials handling system that minimizes

costs with room to expand in the future

utomatic guided vehi-cles or AGVs have been a staple of materi-als handling in a manu-

facturing environment for decades Itrsquos not uncommon to find a fleet of 20 or more vehicles delivering product to the assembly line in a large automo-tive plant

But AGVs in a distribution cen-ter Not so much In DCs they have largely been relegated to mov-ing product from the plant to an adjoining DC That may be about to change if the 420000-square-foot distribution center opened by Del Monte Foods in Topeka Kan last October is any indication

There Del Monte has put to work a fleet of 39 laser-guided AGVs (Elettric80 uselettric80com)

bull Four conveyor-topped vehicles

ferry loads of pet products from an adjacent manufacturing plant to a transfer conveyor in the distribution center There the loads are automati-cally placed on pallets and staged for putaway in the DC Each vehicle can carry four loads at a time

bull An additional 35 fork-equipped vehicles handle most of the tasks usu-ally performed by lift trucks in a con-ventional distribution center They automatically put loads away into stor-age locations on the floor or in pallet rack replenish pallet pick locations in pick aisles and deliver full pallet picks to a staging area in the shipping area

Both vehicle types use a laser-guided navigation system to direct travel through the facility Lift trucks still play a role loading and unloading trailers at the dock and filling orders for mixed-case pallets

BestINclass

MMH1010_SystemRptDelMonteindd 19 101210 323 PM

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

bull Discover the newest robotics products and services bull See the latest robot-based solutions for picking and palletizing bull Understand how intelligent robots are revolutionizing processing

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Sponsoring companies include

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ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

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Modern Materials HandlingMotion Control RoboticsNational InstrumentsOmron Scientifi c Technologies IncRobotics TrendsWind RiverYaskawa Motoman Robotics

MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

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Holster YourSide Arm

or a slingerright or left

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Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

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2 PLY THREAD DESIGN

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8002272906 Video Conferencingsuperiorbandsbellsouthnet

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C

M

Y

CM

MY

CY

CMY

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classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

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bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

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As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 21: Modern Materials Handling - October 2010

modern system report

ldquoThis was a greenfield facility which gave us a unique opportunity to design a facility that leverages innovation and technology from day onerdquo says Keith Arntson Del Montersquos vice president of distribution operations ldquoWe believe this is one of the largest if not the larg-est installations of AGVs in a distribu-tion center in North Americardquo

After less than a year of operation the system is delivering a number of benefits including exceptional uptime accuracy and reduced product damage

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo says Arntson ldquoOur damage rates are significantly lower than in our conventional facilitiesrdquo

Streamlined operations The Topeka distribution center was first conceived as a network optimiza-tion project The manufacturing plant in Topeka had no warehouse space Instead pet products manufactured in Topeka were shipped to forward distri-bution centers in Chicago Texas and Georgia

Some of that product however would end up retracing a route back to the Midwest to fill customer orders About three years ago Del Monte began looking at ways to take miles out of its network The goal was to lower

the delivered cost of its prod-ucts and reduce the lead times it could offer to customers ldquoOnce we completed the network study the Midwest offered us the greatest opportunity for supply chain efficienciesrdquo says Arntson ldquoWe still ship product to forward DCs in other parts of the coun-try but in the Midwest we can ship directly to our customersrdquo Likewise the DC acts as a for-ward DC for other complementary Del Monte products that are not manufac-tured in Topeka

Once the decision was made to locate in Topeka the Del Monte team worked with a design and integration firm to develop materials handling pro-cesses and systems that would mini-mize the amount of times the product was handled in the facility maximize labor and easily scale as throughput at the DC grows in the future

ldquoWe were tasked with building a best-in-class DC that utilized proven innovation and produced the lowest delivered cost so we could remain com-petitive in the marketrdquo Arntson says

To meet those goals Del Monte

modeled a range of options from a traditional warehouse to an automated storage and retrieval system (ASRS) to the AGVs Careful attention was also paid to everything from the light-ing to how the trailers were laid out in the yard

To learn more about AGVs the team visited a number of manufacturing sites that were using laser-guided vehicles in part because no distribution center was using the technology to the extent that it would be used by Del Monte According to Arntson the laser-guided technology stood out for three reasons

First it was precise ldquoOur AGVs donrsquot just take a load to location Xrdquo Arntson says ldquoThey go to a specific location on the floor to within a centi-meter and they do that time and time againrdquo That precision not only meant more accurate inventory and storage information it also meant that product

ldquoThe system is performing at 9999 uptime which was higher than we expected and the system has been 9999 accuraterdquo mdash Keith Arntson vice president of distribution operations Del Monte

Lift trucks are limited in use to the docks and case picking

20 O c t O b e r 2 0 1 0 Modern MateriaLs HandLing mmhcom

MMH1010_SystemRptDelMonteindd 20 101210 323 PM

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

bull Discover the newest robotics products and services bull See the latest robot-based solutions for picking and palletizing bull Understand how intelligent robots are revolutionizing processing

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ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

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Modern Materials HandlingMotion Control RoboticsNational InstrumentsOmron Scientifi c Technologies IncRobotics TrendsWind RiverYaskawa Motoman Robotics

MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 22: Modern Materials Handling - October 2010

modern system report

was unlikely to be damaged as it was moved around the facility

Second AGV technology was mature proven and predictable ldquoThe feedback we got from end users made us realize that this was no longer bleed-ing-edge technologyrdquo Arntson says ldquoWe saw vehicles that had been fully opera-tional in a 247 environment for years and were very efficient and successfulrdquo

Third because Topeka would be a 247 operation Del Monte could more easily justify the capital investment

In the end AGVs offered the best opportunity to meet the goals for the new DC Whatrsquos more the technol-ogy could easily scale in the future ldquoIf our business grows in the future all we have to do is add another vehicle to keep up with demandrdquo says Arntson

Putting AGVs to work Installing a fleet of 39 laser-guided vehi-cles involved more than unloading them from the truck and flipping a switch For starters to get the most from the vehi-cles the location layout and installation of the storage areas including the rack system had to be very precise ldquoIf you install racking in a traditional warehouse you can be a little offrdquo says Arntson ldquoThe specifications have to be spot on to work with AGVsrdquo

Exactness is necessary because the vehicles are so precise that any devia-tion in the level of the floor or the loca-tion of a rack can throw off the naviga-tion system

More importantly says Arntson Del Monte wanted to do more than

just maximize the labor requirements for the new facility the company also wanted to get the same kind of opera-tional efficiencies from the vehicles that it would get from a Tier 1 ware-house management system (WMS) managing tasks in a conventional ware-house ldquoWhatrsquos important isnrsquot just that yoursquore using automated equipmentrdquo he says ldquoItrsquos also how well you utilize the equipment to accomplish tasks and drive down mission timesrdquo

In Del Montersquos facility the WMS and the AGV control system work together on task interleaving when a vehicle completes a task the system chooses its next assignment based on the next closest task to be completed That minimizes empty travel time and maximizes the use of the equipment

ldquoWe have a large tele-vision monitor in the control room that shows where the vehicles are at all times and allows us to watch the entire building operaterdquo says Arntson ldquoThat allowed us to iden-tify bottlenecks in our original design and then prioritize tasks and imple-ment strategies within the WMS to drive down mission timesrdquo

That work was done collectively by Del Monte the systems integrator and the AGV provider ldquoWe were able

to get through the learning curve very quicklyrdquo says Arntson ldquoIn a matter of three or four weeks we had fine-tuned our processes and had full task inter-leaving in placerdquo

With nearly a year of operation under their belt Arntson says the project is meeting its goals ldquoWe set out to build a best-in-class distribu-tion center that allows us to reduce waste at all levels with a low delivered costrdquo Arntson says Beyond that he adds ldquowe have significantly reduced our network miles which is a sustain-ability play and wersquore closer to our customers to respond to their swings in demand Wersquore now best-in-class on many of our customer score cards out of that siterdquo

Del Monte relies on more than 30 fork-equipped AGVs for putaway and pallet picking in the

distribution center

MoDern MAteriAls HAnDlinG O c t O b e r 2 0 1 0 21

MMH1010_SystemRptDelMonteindd 21 101210 323 PM

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

bull Discover the newest robotics products and services bull See the latest robot-based solutions for picking and palletizing bull Understand how intelligent robots are revolutionizing processing

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ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

Denso RoboticsElite EngineeringFANUC RoboticsFood EngineeringGenesis Systems GroupHartness InternationalKIva Systems

Modern Materials HandlingMotion Control RoboticsNational InstrumentsOmron Scientifi c Technologies IncRobotics TrendsWind RiverYaskawa Motoman Robotics

MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

chepcomsimplechoice

Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

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MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 23: Modern Materials Handling - October 2010

22 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

modern system report

dock The load is palletized scanned and staged for pick up and putaway

Putaway Palletized loads are picked up by one of 35 fork-equipped vehicles The AGV is then directed to a rack or floor storage location (4) based on pre-defined locations in the facilityrsquos warehouse management sys-tem (WMS) Locations are prioritized based on whether the product is a fast- medium- or slow-moving item No bar code scan is required to con-firm the putaway by the vehicle since

A fleet of 39 laser-guided automatic guided vehicles (AGVs) has stream-lined the materials handling processes and reduced the number of touches in Del Montersquos highly automated new dis-tribution center in Topeka Kan

receiving The Del Monte distribu-tion center receives product from the adjacent manufacturing plant (1) and at the shipping and receiving area (2) from other Del Monte manufacturing facilities Locally manufactured prod-uct is automatically loaded onto a slip sheet stretch-wrapped and staged on

a discharge conveyor (1) One of four conveyor-topped vehicles interfaces with the discharge conveyor to pick up a load Each AGV can carry four loads Once the vehicle has picked up all of its loads it travels through a 75-foot breeze-way connecting the DC to the plant and drops the pallets at a transfer sta-tion (3a) There the slip-sheeted loads are placed on a pallet automatically scanned and staged for pick up and put-away At the receiving dock slip-sheeted loads are unloaded by lift truck and placed on a transfer station (3b) on the

Automatic guided vehicles streamline operations Laser-guided AGVs move product from the manufacturing plant and through the distribution center

By Bob trebilcock Executive Editor

del Monte Foods topeka Kan

size 420000 square feet of distribution space

Products Pet products

sHiFts 7 days 24 hours

eMPloyees 50 in distribution

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

MMH1010_SystemRptDelMonteindd 22 101210 323 PM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

bull Discover the newest robotics products and services bull See the latest robot-based solutions for picking and palletizing bull Understand how intelligent robots are revolutionizing processing

packaging plant operations and material handling bull Learn about robotics solutions that will increase your bottom line

Sponsoring companies include

Register TodaymdashItrsquos FREE Go to robovirtualeventscom

ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

Denso RoboticsElite EngineeringFANUC RoboticsFood EngineeringGenesis Systems GroupHartness InternationalKIva Systems

Modern Materials HandlingMotion Control RoboticsNational InstrumentsOmron Scientifi c Technologies IncRobotics TrendsWind RiverYaskawa Motoman Robotics

MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

chepcomsimplechoice

Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

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YOUR ONE EVENT FOR

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ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

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MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

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2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 24: Modern Materials Handling - October 2010

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 23

modern system report

615

Transferstation

Receivingfrom plantDischarge conveyor

1

Shippingand receiving

2

Storage 4

Storage 4

Storage 4Transferstation

3bTransferstation

3b

Staging5

Staging5

Pick aisles6

Staging5

Transferstation

3a

3a

AGVE CB10 CB12 chopper and motor repair parts amp service

North American Representative

wwwamerdencom

salesamerdencom

904-826-4490 Fax 904-826-4491

Retrofit of large vehicles with new controls and wiring done on site

New offboard AGV system software

traffic control and IOrsquos as well as system expansions

Stack pallets up to

36rsquo high in warehouse

lanes

AGV to fork truck

collision avoidance

control available

Custom AGV Specialists New or Retrofit

mmhcom MODERN MATERIALS HANDLING A P R I L 2 0 1 0 47

programmable optical sensors for safe operation near pedestrians and in confined spaces The AGVs follow a self-adhesive magnetic tape for simple setup with no floor modifications Toyota Material Handling 800-226-0009 wwwtoyotaforkliftcom

Robotic pallet truck handles 8000 poundsThe vision-guided GP8 robotic pallet truck frees skilled employees by performing non-value-added work by auto-mating pallet transport After an operator positions the vehiclersquos 96-inch long forks under the pallet the industrial mobile robot transports pal-lets to an assigned location automatically positions them and returns to the original starting pointmdashor other pre-assigned locationmdashfor more work The vehicle handles up to 8000 pounds and stores 25 miles of learned routes

AGVs

Your Complete Lifting Solution

Visit wwwpositechcom

TaurusShown with Optional Pedestal Mount

SAMShown with Optional Pedestal Mount

Transfer Arm

ReactionArmShown with Optional Pedestal Mount

LodeArmShown with Optional Trolley Mount

Powered by a 24-volt DC battery the vehicle travels at a maximum speed of 35 miles per hour Seegrid 877-733-4753 wwwseegridcom

Roller forks handle palletless loads

Using a patented roller fork mecha-nism the pallet-free automatic guided vehicle eliminates the need for pallets within a facility The vehicle handles loads on slip sheets and offers stacking and push back rack capability It may also be used for pal-let handling The automated system reduces labor costs product damage and operational costs HK Systems 262-860-6715 wwwhksystemscom

MMH100401ProdFocus_ID 47 482010 113513 AM

system suppliers

autoMatic guided veHicles elettric80 847-329-7717 uselettric80com

systeMs integrator Peach state 800-998-6517 wwwpeachstatecom

transfer conveyor systec conveyors 800-578-1755 wwwsystecconveyorscom

rack unarco Material Handling 800-862-7261 wwwunarcorackcom

WareHouse ManageMent systeM eXe technologies (infor) 678-319-8000 wwwinforcomsolutionsscmwms

lift trucks yale Materials Handling 800-233-9253 wwwyalecom

Bar code scanning accu-sort systems 215-723-0981 wwwaccusortcom

the system is nearly 100 accurate Once the AGV drops off a pallet load the system knows that it is available for the next task

Picking As with receiving pick-ing may be done using automation or conventional processes Full pallet picks are handled by the AGVs The system directs a vehicle to a floor or rack storage location (4) The pallet is then delivered to a staging area (5) in the shipping area or to replenish a pick location in one of the pick aisles (6) that run the length of the building

Mixed-SKU orders calling for mixed pallets are fulfilled using con-ventional processes The WMS deliv-ers picking instructions including the location and the quantity of cases to be picked in the pick aisles (6) to order selectors on RF devices Cartons are picked to pallet Once the pallet is complete itrsquos stretch-wrapped and

staged (5) in the shipping area shipping Once pallets are built

stretch-wrapped and staged in ship-

ping the system directs lift truck operators to load the pallets onto trailers (2) M

MMH1010_SystemRptDelMonteindd 23 101210 323 PM

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

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Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

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MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

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Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

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2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

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Y

CM

MY

CY

CMY

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Label Holders Load Transfer Systems

Career Opportunities

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Donrsquot Cost - They Pay

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VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

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ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

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WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

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Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

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To advertise or for more

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Jennifer Drevline

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jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

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MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 25: Modern Materials Handling - October 2010

KEYNOTE SPONSORS

PRODUCED BY

OCTOBER 27 2010 900amndash530pm EST

New Applications for Industrial RoboticsVirtual Conference amp Exposition

robovirtualeventscom

The Future of Packaging Warehousing and DistributionCome Meet the Robotics Technology LeadersmdashItrsquos All Online and FREE

Donrsquot Miss This Featured Session Presentation

Trends in Automation The Emerging World of Robotic Materials Handling Presented by Bob Trebilcock Modern Materials Handling

From the receiving dock to pick modules to palletizing the robots are coming In a tough economic environment materials handlers are investigating ways to put mobile and overhead robots to work in the plant and distribution center In this session Bob Trebilcock executive editor of Modern Materials Handling magazine will look at the emerging world of robotic materials handling whether the technology is hype or real and at what types of applications and operating environments are ripe for a robotic solution

The New Applications for Industrial Robotics Virtual Event gives you live online access to one of the most important events for materials handling professionals

bull Discover the newest robotics products and services bull See the latest robot-based solutions for picking and palletizing bull Understand how intelligent robots are revolutionizing processing

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Sponsoring companies include

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ABB RoboticsAdept Technology IncAmerden AGVSAutomationcomAutomotive Design amp ProductionDenso ADC

Denso RoboticsElite EngineeringFANUC RoboticsFood EngineeringGenesis Systems GroupHartness InternationalKIva Systems

Modern Materials HandlingMotion Control RoboticsNational InstrumentsOmron Scientifi c Technologies IncRobotics TrendsWind RiverYaskawa Motoman Robotics

MM1010 ppxx RoboVTSindd 1 93010 52356 PMMMH1010_Adsindd 24 101210 1053 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

chepcomsimplechoice

Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

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Find us on

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MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

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2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 26: Modern Materials Handling - October 2010

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 25

modern productivity solution

Kaiser Aluminum which has been providing aluminum components to the aerospace man-

ufacturing and industrial markets since 1946 pro-duces several different types of aluminum automo-tive parts at its facility in South Carolina During the manufacturing process parts are transported to workstations in large wire baskets for further processing like stamping bending and heating To get a part a worker bends over and reaches down into a basket to lift it out As the level of parts in a container drops workers must bend lower and reach deeper

This action can not only cause fatigue and strain it can rob valuable time from the production pro-cess Concerns about the potential for employee back injuries and production-line bottlenecks led Kaiser management to investigate ergonomic solu-tions for their workers and an improved production process for their business

Company managers met with equipment suppli-ers to evaluate the current manufacturing process and identify solutions During the equipment evalu-

ation phase an animated 3-D video showed exactly how tilters (Presto Lifts wwwprestoliftscom) could solve ergonomic and production issues

The tilters permit workers to pick out parts by bending only slightly using a push-button hand-held pendant or pedestal-mounted controls to hydraulically adjust the unit to the most convenient angle (up to 89deg) as the container is depleted so parts are kept within easy reach With unrestricted access to the contents there is virtually no risk of back injury

Kaiser purchased a variety of tilters some of which also lift All models are designed to provide easy access to parts in large containers Workstations vary so different models were chosen to keep parts at the most convenient level at each location A full container can be easily placed on any unit with a hand pallet truck or lift truck

Since installing the ergonomic lifting and tilt-ing equipment management reports that bottle-necks have been eliminated and production lines have sped up M

TilT Toward safeTy and producTiviTy

By Lorie King Rogers associate editor

Aluminum parts manufacturer uses ergonomic lifting equipment to prevent worker injury and increase production

MMH1010_ProdSolindd 25 101310 941 AM

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

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Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

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2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

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C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

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L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

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To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

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bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

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  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 27: Modern Materials Handling - October 2010

26 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

By Bob trebilcock Executive Editor

Top 20

The ADC market took

a significant hit in 2009

but the recovery may

already be underway

modern special report

automatic data capture suppliers

MMH1010Top20_ADC2indd 26 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

chepcomsimplechoice

Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

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48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

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Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

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MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

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Holster YourSide Arm

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classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

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Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

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As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

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  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 28: Modern Materials Handling - October 2010

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 27

declined through much of 2009 all of the categories VDC tracks began to grow again modestly by the end of the year Emphasis again on the word ldquomodestrdquo

With business on the ropes most major players focused on maintaining

the status quo there were no major mergers or acquisitions last year and no real departures from technologies or markets

Likewise the 2009 market leaders included familiar faces Once again

modern special report

Reality bites and in 2009 the automatic data capture busi-ness was bit hard The total market for industrial automatic data capture (ADC) solutions

came in at roughly $152 billion in 2009 according to Massachusetts-based VDC Research Group (wwwvdcresearchcom) down about 155 from the more than $18 billion spent on industrial ADC in 2008

But it was a tale of two years and a modest recovery may already be under-way buoyed by investments in RFID technology and 2D imaging solutions according to Drew Nathanson VDCrsquos director of research operations The emphasis is on the word ldquomodestrdquo ldquoThere is still a lot of uncertainty about the economic recovery and that impacts this marketrdquo says Nathanson

The ADC market includes handheld and stationary bar code scanning and imaging devices bar code printers con-sumables like bar code labels and RFID tags RFID solutions for the supply chain and ruggedized mobile computing solutions for the factory and warehouse

As Nathanson notes the recession didnrsquot hit the ADC industry until the fourth quarter of 2008 And while there is no question that solution providers

Top 20 ADC suppliers by revenue ($ millions)

Rank CompanyTotal 2009 Revenues Web site

1 Motorola $10740 wwwmotorolacom

2 Zebra $4343 wwwzebracom

3 Intermec $3650 wwwintermeccom

4 DatalogicPSC $3284 wwwdatalogiccom

5 Honeywell (HHP) $3080 wwwhoneywellcom

6 SATO $2230 wwwsatoamericacom

7 TEC $1669 wwwtecamericacom

8 Psion Teklogix $1551 wwwpsionteklogixcom

9 SAVI $1479 wwwsavicom

10 Avery Dennison $1234 wwwaverydennisoncom

11 Printronix $1138 wwwprintronixcom

12 Denso Wave $1104 wwwdenso-wavecom

13 LXE $890 wwwlxecomw

14 Vocollect $855 wwwvocollectcom

15 Datamax-OrsquoNeil $732 wwwdatamaxcorpcom

16 Siemens $635 wwwusasiemenscom

17 Casio Computer $599 wwwcasio4businesscom

18 Mobilecompia $545 wwwm3mobilecokr

19 Bluebird Soft $512 wwwmypidioncom

20 Unitech $381 wwwutecomSource VDC Research Group

automatic data capture suppliers

MMH1010Top20_ADC2indd 27 101310 943 AM

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

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SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

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MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 29: Modern Materials Handling - October 2010

tings like hospitals libraries or resorts Nor do we include companies that only manufacture consumables like bar code labels and RFID tags

While the overall market for ADC solutions totaled $152 billion each of the industry segments experienced their own dynamics last year that may have been different from the overall market

Mobile computingThe market for ruggedized mobile com-puters reached $19 billion in 2009 says David Krebs VDCrsquos director of the mobile and wireless computing practice Approximately $500 million of the mar-ket is attributed to solutions on the plant or DC shop floor or in port and yard applications while stationary devices for lift trucks accounted for about $180 million in 2009 Both figures represent significant declines from 2008 with the handheld market down about 24 and the lift truck-mounted market down by roughly 31 a figure that comes close to mirroring the decline in lift truck sales last year

However the market has begun to improve Krebs estimates that the mar-ket for handheld devices will grow by a compound annual growth rate (CAGR) of 84 through 2014 with the lift truck market growing by 58 per year

The economy rather than any new technological development dominated the news in this space last year ldquoBusiness conditions across the board were very challengingrdquo says Krebs ldquoAnd when it comes to the warehousing manufactur-

ing and logistics space these are increas-ingly mature markets While there is some growth in emerging markets the replacement and upgrade market is driv-ing much of the business not expansionrdquo

However Krebs is watching the impact of smart phone technology on ruggedized mobile computers ldquoThe rapid growth of the iPhone and Android operating systems in the consumer mar-ket is beginning to impact the industrial marketrdquo says Krebs At the same time he adds most of the initial applications have to do with field service ldquoWhile the products they design for those environ-ments could impact warehouse prod-ucts I think the warehouse is one of the last places yoursquoll see these devices take holdrdquo he says

The market for wearable computers a category that includes voice recogni-tion technology totaled $175 million last year a drop of about 10 from 2008 Adoption of voice and wearable solutions saw a big run-up in 2007 and 2008 especially in consumer packaged goods industries While Krebs contin-ues to see a great deal of interest in voice it is still a niche market

ldquoOne of the challenges to adoption has been the high cost of dedicated voice terminals versus a voice-enabled mobile computerrdquo he says ldquoStill wersquore seeing interest especially in multi-modal envi-ronments that leverage voice bar codes and other ADC technologiesrdquo

Scanning and printingThe markets for bar code-related hard-ware saw some of the most significant

28 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Motorola (wwwmotorolacomus) led with an estimated $1074 billion in rev-enue Motorola was followed by Zebra Technologies (wwwzebracom) with $4343 million The top five was rounded out by Intermec Technologies (wwwinter-meccom) which recaptured the No 3 spot with $365 million DatalogicPSC (wwwdatalogiccom) with $3284 million and Honeywell with $308 million accord-ing to estimates provided by VDC Printer maker SATO which had been No 3 dropped to No 6 with $223 million

Collecting the data This is Modernrsquos ninth-annual look at the leading manufacturers of ADC hard-ware and solutions Because the industry includes public and private companies this is the second year in a row that we asked VDC Research Group to compile the data Since their analysts are cover-ing this technology every day they are closer to the market

To make our list companies must sell in North America though the chart includes worldwide revenues Modern does not include resellers systems inte-grators or other companies that do not manufacture ADC hardware Since our readers are primarily focused on supply chain solutions we do not include com-panies whose primary focus is the retail checkout counter or non-industrial set-

modern special report

ldquoBusiness conditions across the board were very challenging and when it comes to the warehousing manufacturing and logistics space these are increasingly mature marketsrdquo

mdashDavid Krebs VDCrsquos director of mobile and wireless computing practice

MMH1010Top20_ADC2indd 28 101310 943 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

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COVERELASTIC COREYARN

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  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 30: Modern Materials Handling - October 2010

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 29

modern system report

Top 20 ADC suppliers and what they make

Rank CompanyBar code printers

Handheld scanners

Stationary scanners RFID

Mobile computers

1 Motorola

2 Zebra

3 Intermec

4 DatalogicPSC

5 Honeywell (HHP)

6 SATO

7 TEC

8 Psion Teklogix

9 SAVI

10 Avery Dennison

11 Printronix

12 Denso Wave

13 LXE

14 Vocollect

15 Datamax-OrsquoNeil

16 Siemens

17 Casio Computer

18 Mobilecompia

19 Bluebird Soft

20 Unitech

Source VDC Research Group and Modern Materials Handling

declines in 2009 Handheld scanners dropped 226 from 2008 to $6275 million the second drop in a row while the market for industrial fixed scan-ners declined by 25 to $6604 million according to Tom Wimmer director of VDCrsquos AIDC and RFID practices Meanwhile the market for industrial printers which includes bar code print-ers and the RFID printerencoder mar-ket declined by 22 to $16 billion While all three markets have begun to recover Wimmer is predicting five-year compound annual growth rates of between 56 (printers) to 61 (hand-held scanners)

The one bright spot was in the 2D and camera-based imaging space which grew by an estimated 20 last year ldquoWhat that says to me is that end users are beginning to get excited by imaging technology and the benefits it can pro-viderdquo says Wimmer Imaging technology allows end users to capture more data using 2D bar code symbology or capture images for merchandise returns work-in-process or quality control

As with the mobile computing and voice spaces there was very little busi-ness news And as with mobile com-puting the most important trend is the interest in multi-modal data collection ldquoWe continue to see new processes driven and controlled by bar codes being complemented by voice and RFIDrdquo says Wimmer ldquoThese are viable solutions in the materials handling space and itrsquos going to continue to growrdquo

RFIDIf there was one major bright spot in the ADC market last year it was RFID How good was business ldquoItrsquos going gang-bustersrdquo says Nathanson ldquoThe RFID industry certainly bounced back quicker than the bar code mobile com-puting and printer industriesrdquo

The total RFID market came in at roughly $36 billion including an estimated $3 billion in the industrial and transportation space That was up about 7 from 2008 says Nathanson who expects the market to grow at a compound annual growth rate of 195 to $75 billion by 2014 By the end of 2009 many suppliers were reporting full pipelines with some backlogs in the RFID tag and tran-sponder markets

The key driver is early adopters are seeing real value from the additional data that can be placed on an RFID chip versus a bar code from the vis-ibility that comes from tracking an item throughout the supply chain or its life cycle and from reductions in theft and counter-fitting ldquoApparel manufactur-ers in particular are looking to RFID

to track their product from the point of manufacture through the point of sale so they know when something enters the supply chain and when it is removedrdquo says Nathanson

Just as companies are combining bar codes and voice to create and con-trol new processes RFID is being used with sensors to not only track the loca-tion of an item in the supply chain but to monitor important environmental conditions like the temperature in the cold chain and even carbon emissions for sustainability

ldquoCompanies that made an early commitment to RFID now see it as a competitive advantagerdquo says Nathanson ldquoThey are using the down economy as an opportunity to continue to invest and get new economies over their competitorsrdquo M

MMH1010Top20_ADC2indd 29 101310 943 AM

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

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46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

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WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

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TWISTED O-RINGS

NO TOOLS REQUIRED

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Career Opportunities

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  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 31: Modern Materials Handling - October 2010

30 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

ith ongoing pressures to drive costs out of manufacturing and dis-

tribution processes facilities increas-ingly rely on a blend of data capture and mobile computing technologies to gain better control of assets and inven-tory The application of a single solu-tionmdashsuch as RF bar code scanning imagers voice-directed picking or radio frequency identification (RFID)mdashdeveloped into a blending of technolo-gies embedded into a single device for maximum labor flexibility and opera-tional efficiency

Users need data capture and mobile computing solutions that generate enhanced supply chain visibility and overall business efficiency improve-ments says Mike Liard RFID prac-tice director at ABI Research (wwwabiresearchcom) ldquoTo do that sup-pliers have become more lsquotechnology agnosticrsquo offering a broader range of automatic identification data collection (AIDC) solutions for use in combina-tion as complementary technologiesrdquo

ldquoThe technologies are used not just to find assets but also to track the mis-

sion-critical things that get tied to your processrdquo Liard adds ldquoPeople are looking beyond labor cost reduction to overall cost reductionmdasha more holis-tic approachrdquo

Further ldquotherersquos been a trend to have devices that can operate 24 by 7 by 365 or with essentially no downtimerdquo says Tim Eusterman senior direc-tor of industry marketing for Intermec (wwwintermeccom) ldquoCompanies call it lsquosweating the assetsrsquo and theyrsquore look-ing get the most utilization out of the least amount of investment in mobile computingrdquo

Multi-modal capabilitiesFeeling the pressure to run as lean as possible has companies examining every angle of their spending

ldquoAlong with that therersquos a reduction in information technology (IT) staff and IT spendrdquo says Dave Peddemors vice president of North American sales for Psion Teklogix (wwwpsionteklogixcom) ldquoUsers upgrade because they canrsquot support their old systems any-

MODERN information management

By Sara Pearson Specter Editor at Large

Using a combination of diverse technologiesmdashoften in one compact packagemdashgives users the edge in asset management and operational efficiency

W

MMH1010InfoMgmtindd 30 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

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YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

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ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

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MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

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Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

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C

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Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

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Brian ceraolopublisher bceraoloehpubcom

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salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

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career Opportunities

To advertise or for more

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Jennifer Drevline

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MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

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As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

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  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 32: Modern Materials Handling - October 2010

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 31

more they may not have an IT staff person in every single location So companies are looking at modularity and the ability to deploy one platform across multiple applicationsrdquo

In response vendors are provid-ing smaller faster data capture and mobile computing devices with multi-modal functionalitymdashcombining RF scanning imaging RFID tag reading voice-directed picking and other AIDC elements into a single unit One device has one operating system battery pack holsters and modular accessories to

simplify management of the tools Peddemors says

A single multi-modal device also offers flexibility says Intermecrsquos Eusterman ldquoSome mobile computers can be used on a forklift for receiving putaway and replenishment then can also be a wearable device for a voice pick-ing application Or in a receiving situa-tion if a user is more comfortable with a pistol grip that can be attached to con-vert the device to a hand heldrdquo he says

More units are incorporating imager cameras as well according to Motorolarsquos

Mike Maris senior director of transpor-tation and logistics (wwwmotorolacomenterprise) ldquoEspecially at the docks the ability for a receiving clerk to take pic-tures of a delivery in real time combine it with a voice recording and send a mes-sage to the buyer to confirm the accuracy of the receipt through the mobile com-puter is a real timesaverrdquo he says

Browser-based interfacesOperators of mobile computers have become quite familiar with browser-based navigation and smart

modern information management

Wearable mobile computing devices are increasingly being enhanced with greater processing power and more memory to accommodate full color images that show a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow in building a pallet load

MMH1010InfoMgmtindd 31 101310 1051 AM

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

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MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

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Holster YourSide Arm

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Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

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C

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CY

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Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

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Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

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salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 33: Modern Materials Handling - October 2010

32 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

phones Because of that inherent comfort level ware-house devices are also sport-ing these interfacesmdashmaking them both more accessible to new users and easier to train employees on

Additionally warehouse management system (WMS) solution providers have begun offering the ability to present full color images on mobile computersmdashshowing a visual of the product to be picked the correct location of a pick or the appropriate scheme to follow-ing in building a pallet load to name a few

To accommodate these fea-tures ldquothe devices have more processing power and more memoryrdquo says Keith Bernhardt LXErsquos director of product man-agement (wwwlxecom) ldquoIf you have a higher powered proces-sor you can deliver more com-mands faster for quicker tradi-tional picking If the device is a thicker client you canrsquot afford to slow down just because you have a few more featuresrdquo

Look for newer devices to also sport higher resolution screens says Psion Teklogixrsquos Peddemors ldquoVendors are developing high-visibility high-resolution screens that represent the product very well and allow you to get a lot of legible readable data in that screen factorrdquo he adds

InterconnectivityBluetooth technologies continue to be employed with mobile computing and data capture devices says LXErsquos Bernhardt ldquoTo enable the interaction of different equipment Bluetooth con-nects scanners to vehicle mounted and hand-held computers so operators no longer have to be tethered to a forkliftrdquo he says

The technology also enables opera-tors to wear hands-free devices such as

ring scanners on their fingers or voice-enabled headsets over their ears that communicate back to a computer worn on a belt ldquoThat combination allows the wearer to be really mobile more efficient work faster and make the operations move much more smoothlyrdquo Bernhardt adds

Also enhancing interconnectiv-ity says Tom Burke vice president of product marketing at Datalogic Mobile (wwwdatalogiccom) are the location-based service technologies that can be integrated on mobile computing and data capture devices

ldquoThe combination of global position-ing systems (GPS) with cellular tech-nologies and Wi-Fi positioning systems opens up a lot of opportunities to know

the position of a person relative to a position within a facilitymdashwith-out putting in an expensive dedi-cated location-based systemrdquo Burke explains ldquoThese solutions also allow you to instantly know a vehicle location for tracking par-cel deliveriesrdquo

The systems seamlessly main-tain the wireless connection enabling an appropriately equipped mobile worker to complete tasks inside the warehouse and then out in the yard

For even more productivity operators can be outfitted with a fast-output mobile printer that wirelessly networks with mobile computers and prints human-readable or bar code labels for shipping returns or store location loading

ldquoIf you outfit the worker with a mobile printer you can really cut down on travel time to fixed printers and eliminate confusion in locating loads that are some distance awayrdquo adds Intermecrsquos Eusterman

RFIDrsquos re-emergenceAlthough still considered by some to be a four-letter word RFID tags and reader use is

exploding as a component of data cap-ture for asset managementmdashinclud-ing inventory work-in-process parts returnable packaging tooling and vehi-cles says ABI Researchrsquos Liard While the trend is fueled partly by an increase in the technologyrsquos reliability and a corresponding decrease in per-tag and reader costs companies are evaluating RFID based on return on investment and total cost of ownership

ldquoThe value of the tagged asset is certainly going to come into play but therersquos also the factor of preventing the loss of assets or having trouble find-ing these assets during mission-critical timesrdquo Liard says ldquoThe value proposi-tion is tied to the business process and the larger efficiency picturerdquo

modern information management

to give users the ability to deploy one platform across multiple applications mobile computing vendors are providing smaller faster data capture devices with multimodal functionality

MMH1010InfoMgmtindd 32 101310 1051 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

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classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

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2 PLY THREAD DESIGN

COVERELASTIC COREYARN

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QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

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Label Holders Load Transfer Systems

Career Opportunities

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Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

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To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

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Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

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L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

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Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

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career Opportunities

To advertise or for more

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MMH1010_Classifiedindd 3 101210 346 PM

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bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

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As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

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Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

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  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 34: Modern Materials Handling - October 2010

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 33

Warehouses and manufacturers are looking for mobile computing solutions that enable them to better manage inventory assets and labor agrees Toby Rush president and CEO of Rush Tracking Systems (wwwrushtrack-ingsystemscom)

Rushrsquos company offers a solu-tion featuring an RFID reader mounted to the top of the lift truck for indoor position monitoring and real-time visibility of the truck and an RFID reader mounted on the front of the vehicle or on its forks automatically scans the load being moved ldquoBy taking away the hand-held bar code scanner and not making a person scan a facility can gain speed and accuracy by elimi-nating errorsrdquo Rush explains

In addition to inventory and shipping accuracy improvements users of these systems also benefit from analyzing the data collected to yield better labor and fleet management adds Rush ldquoItrsquos like having a little industrial engineer

riding on every forklift doing time studies all day longrdquo

Information dense bar codesWith growing use of information-dense bar codesmdashsuch as two-dimensional (2D) ver-sions that store informa-tion both horizontally and vertically and com-pact GS1 DataBar (for-merly known as RSS reduced space symbol-ogy)mdashadditional infor-mation can be stored in the mark Application identifiers contain more information than ever before such as serial numbers lot numbers and expiration dates that yield better product identification quality

control and traceabilityTo accommodate these bar codes

data capture devices now incorporate imagers that have become as fast at

reading them as laser scanners read a traditional one-dimensional bar code says Motorolarsquos Maris ldquoThe imagers are essentially cameras that take a pic-ture of the bar code and translate the dots and squares for traceability itrsquos a technology thatrsquos starting to find real purposerdquo

Computing in a cloudWith more WMS vendors looking to offer their software as a service (SaaSmdashalso known as cloud-based computing) most mobile computing device manu-facturers say the effect on their tech-nologies will be negligible

ldquoMost devices now have an inte-grated browser and fairly high speed interface to the networkrdquo says Datalogicrsquos Burke ldquoSaaS requires a cer-tain functionality from your browser and if you have an old one that hasnrsquot been updated yoursquore going to have some compatibility issuesrdquo

Itrsquos also important to verify that the devices have the ability to lock the browser onto a single application preventing users from accessing the Internet or control panel as well as keeping the network secure

Perhaps the biggest benefit of cloud-based computing will be the ability of a smaller level of user to take advantage of warehouse automation says LXErsquos Bernhardt ldquoCertainly SaaS allows smaller deploy-ments to take place in larger numbersrdquo he adds

For mobile computing and data capture device manufac-turers that will likely lead to an increased availability of pared down more common configurations of products that donrsquot require as much customization ldquoTheyrsquore not going to be looking for so much specialization and variety but will still find sig-nificant improvement in their operations overallrdquo Bernhardt says M

modern information management

With growing use of information-dense bar codes data capture devices now incorporate imagers that have become as fast at reading them as laser scanners read a traditional one-dimensional bar code

location-based service technologies can be integrated on a device allowing companies to instantly know a vehicle location for tracking parcel deliveries

MMH1010InfoMgmtindd 33 101310 1051 AM

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

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E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

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2 PLY THREAD DESIGN

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VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

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847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

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Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

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salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

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DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

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MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

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MMH1010_Classifiedindd 3 101210 346 PM

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  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 35: Modern Materials Handling - October 2010

ertical and horizontal carousels have been moving product through warehouses and distribution centers for more than 25 years In addi-tion to creating dynamic high-density storage carousels can be cred-ited with increasing productivity reducing labor saving space and

cutting energy costsThe concept of carousel technology hasnrsquot changed much over the years

That might be because a carousel is a robust and dependable piece of equip-ment and it is mechanically pretty simple says Jack Lehr vice president of sales for automated systems for SSI Schaefer (wwwssi-schaeferus) What is changing is how users are applying carousel technology ldquoAbout five years ago however engineers in the United States started to recognize that the goods-to-person process is hands down the most efficient picking pro-cessrdquo says Lehr

So if you have a picking operation are carousels the right solution ldquoAny manufacturing plant warehouse or distribution center currently using a traditional static rack and shelving system should investigate the possibility of incorporating an automated solution like a vertical or horizontal carouselrdquo says Christina Hilligoss marketing and commu-nications manager for KardexRemstar (wwwkardexremstarcom)

And that investigation should cover a few key areas Paul Roy vice president of marketing and product management for

VBy Lorie King Rogers Associate Editor

Not just for high-density storage anymore

todayrsquos carousels are delivering product to the

person while increasing productivity reducing

labor saving space and cutting energy costs

Carousels Turning picking into

modern equipment report

pRoductivity

34 O c t O b e r 2 0 1 0 ModeRN MateRiaLs HaNdLiNg mmhcom

MMH1010_EquipRptCarouselsindd 34 101310 918 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

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Calculate your actual savings by shipping on CHEP

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E-5208RPA

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Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 36: Modern Materials Handling - October 2010

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 35

MODERN equipment report

Turning picking into

System Logistics (wwwsystemlogisticscom) rec-ommends asking Am I currently using labor to pick from shelving Do I have space and accuracy issues Do I need to get orders out the door faster

If you answered ldquoyesrdquo to any of those ques-tions it might be time to consider a carousel ldquoCarousels can go anywhere shelving can gordquo explains Hilligoss ldquoIf yoursquore looking to save space a vertical carousel might be the solution If yoursquore looking to increase productivity horizontal may be the way to gordquo

Either way the starting point is a return on investment (ROI) estimate ldquoCarousels have an average ROI of about 18 monthsrdquo Hilligoss says Whether your return is shorter or longer may depend on your current operations For example are you renting space off site to store product How many people will you be able to retrain and relocate

Common characteristicsBoth vertical and horizontal carousels share key components that are vital to an operationrsquos bottom line

bull They incorporate dense storage technology to house product and components and carousels can save as much as 85 of the space used to store items in traditional static shelving and rack systems

bull Carousels bring products to the person performing a picking or putaway activity and they eliminate the need for associates to walk to retrieve the items needed to fill an order That can cut labor by up to 65 As a rule of thumb one carousel can do the job of five or six people in a conventional process

bull Carousels require precise operator input to confirm guide and control each function and the result is zero-error order picking This avoids the need to re-handle orders and assures high service levels to the customer

bull Carousels are modular and flexible Like building blocks the units can be combined allowing for scalability for a specific project then easily reconfigured when the project requirements change

bull Carousels deliver items to the associatersquos ldquogolden zonerdquo which indicates the ideal ergonomic height That area reduces the potential for injuries associated with excessive reaching and bending a significant bonus for workers although dif-ficult to calculate as part of an ROI analysis

The benefits of carouselsVertical and horizontal carousels have different characteris-tics Yet each brings something different to the storage and order fulfillment table

A vertical carousel rotates up and down or elliptically bringing the right part to the right worker at the right time

PRODUCTIVITYHigh-density storage carousels not only save floor space and optimize vertical space they bring the product to the person which increases throughput and improves picking accuracy

usually delivered in bins totes or on shelves These are ideal for lightweight items because anything too heavy could throw off the unitrsquos balance While small items work well in a verti-cal carousel fragile items do not The constant rapid motion

MMH1010_EquipRptCarouselsindd 35 101310 919 AM

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

chepcomsimplechoice

Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 37: Modern Materials Handling - October 2010

36 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

of the carousel can easily damage deli-cate goods

The true beauty of a vertical car-ousel is that it combines high-density storage and high-speed retrieval tech-nology in a small footprint ldquoVertical carousels are the most effective way

to reduce the amount of space used for small parts storage and gain con-trol of small parts inventoryrdquo says Brian Cohen chief executive at Hanel Storage Systems (wwwhanelus) and also chair of the Material Handling Industry of America (MHIA www

mhiaorg) ASRS industry group More small- to mid-sized compa-

nies are opting for carousels Cohen says ldquoCar dealerships for example are installing carousels to hold spare parts and free up floor space for more work bays which would generate more rev-enuerdquo says Cohen ldquoThe same analogy works for storing production parts or consumables near an assembly station on the manufacturing shop floorrdquo

Take a vertical carousel turn it on its side and you have a horizontal carou-sel These serve the same purpose but because they take up more space they are used more often in manufacturing environments and distribution centers that have space and high throughout and picking demands

ldquoHorizontal carousels are ideal for split case or each pickingrdquo says System Logisticsrsquo Roy ldquoSplit case picking is typi-cally best where replenishment activity is low otherwise whatever you gain in pro-ductivity you lose with replenishmentrdquo

Roy also explains the development of the podless picking concept ldquoIn a typical picking environment a number of horizontal carousels are used to cre-ate a pod and each pod has to be staffed by a personrdquo he explains ldquoWith podless picking we may take a number of car-ousels and install then as an equal face with no defined pod The idea is that we have flexible staffing so that dur-ing a slow time one operator can do all the picking As we get busy during the day or during seasonal peaks we can staff that array of carousels with more people The ability to exercise dynamic flexible staffing is much greater with a podless configurationrdquo

Carousels may also be getting a second look thanks to the interest in sustainability Vertical carousels are

modern equipment report

Batch picking cuts dwell time and increases productivity the carousels spin at different times so when the picker is ready the product is ready

Where will MHE provide the greatest benefitAccording to the Modern 2010 State of Materials Handling Survey Modern readers are seeing a slightly rosier picture in terms of equipment investment Fifty-eight percent of respon-dents reported that they plan to increase their materials han-dling investments over the next three years The largest slice 46 will be invested in picking technology which can often include carousels

3 Loading

4 Recieving

3 Putaway

7 Replenishment

37 Packing

46 Picking

Source Modern Materials Handling Webcast Modern 2010 State of Materials Handling Survey

MMH1010_EquipRptCarouselsindd 36 101310 919 AM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

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PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

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classifiedrecruitment

Label Holders Load Transfer Systems

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VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

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To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

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aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

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MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

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Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

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Holster YourSide Arm

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To advertise or for more

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MMH1010_Classifiedindd 3 101210 346 PM

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As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 38: Modern Materials Handling - October 2010

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 37

incorporating regenerative braking systems that can cap-ture the power that is generated from motors and brakes on the descent and put it back into the power grid And because carousels save space they can store more product in a smaller footprint than with conventional systems One example is an expanded 48-inch bin ldquoBy widening the bin we expose more pick faces to the operator and allow them to fill the order with less movementrdquo says Roy ldquoThere are more SKUs in a bin which minimizes spin time required to retrieve parts and consumes less powerrdquo

New software new strategiesWhile the basic functionality of horizontal and vertical car-ousels has not changed in recent years advances in soft-ware and controls allow end users to make the picking pro-cess more cost effective ldquoWe have decoupled the carousel from the picking processrdquo says Schaeferrsquos Lehr ldquoIn a typical carousel application a person stands and waits for the car-ousel to rotate so they can access the product Wersquove taken the picking workstation away from the carousel and con-nected it with a small conveyor system enough to buffer the incoming product so that product is always available for the pickerrdquo

Software develops the picking sequence so there is a constant steady flow of product from the storage medium to the person doing the picking which cuts dwell time and speeds up productivity

Productivity isnrsquot the only thing picking up speed As the economy makes slow steady progress toward recovery the interest in carousel technology is picking up A lot of companies suffered layoffs during the economic downturn

MODERN equipment report

An operator picks from a pod of horizontal carousels to fill an order The integration of efficient conveyor and sophisticated control technologies assures high stocking and picking rates

says Hanelrsquos Cohen but a lot of companies are able to get back to pre-recession production rates without bringing all the people back Since carousels enable a company to meet customer service levels and demand with fewer associates they can enable that strategy ldquoMany companies have used a bad time to become more efficient And efficiency will pay off well beyond the

return of the economyrdquo He added ldquoIn a global economy we have to be innovative and effective to stay in the gamerdquo

MMH1010_EquipRptCarouselsindd 37 101310 919 AM

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

chepcomsimplechoice

Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 39: Modern Materials Handling - October 2010

38 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

FOCUS ON Palletizers

LM MMH Templateindd 1 10610 400 PM

54 J u l y 2 0 1 0 Modern Materials Handling mmhcom

lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines Dura-Dock loading-dock lifts are offered The units come in 5000- and 6000-

pound capacities and feature galvanized corrosion-resistant base and legs Rising from grade level to a maximum height of 59 inches the lift may be mounted in a concrete pit Platform sizes range from 6 x 8 feet to 8 x 12 feet Features include a weatherproof pushbutton control with 20 feet of coiled cord a diamond-tread steel platform with beveled toe-guards and

removable steel handrails southworth Products 207-878-0700 wwwsouthworthproductscom

Control dock environment with sliding softwallsCreating better environmental control flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas The curtain walls also improve cleanli-ness increase security and contain odors fumes dust or noise Made of heavy-duty industrial vinyl the units are custom fab-ricated for each application and can be reconfigured as facility layout or environ-mental control needs change Mountable to the existing ceiling structure a heavy-duty track and trolley system supports the walls Zoneworks 800-553-4834 wwwzoneworkscom

Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations the CentraPower unit reduces the number of hydraulic pumps disconnects and associated power feeds by a factor of 10 to 1 Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access sim-plified maintenance and lower costs The system features a full backup pump and motor system to ensure continuous up-time systems inc 800-643-5424 wwwdocksys-temsinccom

Cabinet for lean manufacturingFor better workspace organization and management the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies The durable cabinet case fea-tures metal pegboard inserts Alternately solid hinged doors with additional peg-board storage may be specified Stanley Vidmar 800-523-9462 wwwstanleyvidmarcom Booth 2532

44 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Abuse Resistant Belts work where others failSuper Strong Joints are virtually unbreakableHigh Tension Belts move heavier loadsSuper Red Belts double conveyor capacity

Dura-Belt 800-770-2358 614-777-0295Fax 614-777-9448 wwwdurabeltcom

Better thanLifetime Warranty

Longer Lasting Belts

New Split Line-shaft SpoolsHigh precision Reasonable priceEasy to install Zero downtime Can be locked to shaft Eliminatesneed for keyed spools and shafts

MAKE ROOM MAKE ROOM

Maximize storage space with ProHANGERtrade hellip the perfect solution for storing and organizing long parts and supplies

US Patent Pending

Software directs analyzes paperless picking activityExecutives managers and supervisors can easily view pick rate productivity accuracy and throughput with the version 60 release of LP dash-board The software displays real-time updated key performance indicators with drill-down granularity for facility area zone and employee-level views Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data the system offers an automatic slide-show style display of multiple user-configured templates Lightning Pick Technologies 262-250-2143 wwwlightningpickcom Booth 1543

NA 2010 Cleveland

Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control The system delivers inventory to the opera-tor yielding retrieval time savings up to 90 Included standard are lifetime sealed bearings shielded motors secu-rity keypad one-touch forwardreverse wire mesh guarding and obstruction detectors Vidir Machine 800-210-0141 wwwvidircom Booth 3018

Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold preventing product recalls and refused ship-ments The treatment bonds with wood during an elec-trostatic application process making it ideal for pallets used in food and beverage handling consumer prod-ucts pharmaceuticals and paper products X-Mold 866-581-6653 wwwxmoldnet Booth 625

MMH100301ShowProds_IDindd 44 3102010 34909 PM

FOCUS ON dock equipment

Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking leaving operators with their hands free to maximize case picking pro-ductivity At the start of an order the truck delivers a new pallet to the picker Then it automatically moves

with the voice-equipped picker as they verbally confirm picks and transports the completed pallet to shipping while the next truck brings a new pallet to the picker During peak periods pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput As requirements change routing plans can be updated and additional vehicles can be added or transferred between sites Dematic 877-725-7500 wwwdematicus

Low-cost AGVs handle up to 4000 poundsCapable of maneuvering and tow-ing loads throughout a production space a series of low-cost automatic

guided vehicle systems can be con-trolled with traffic control naviga-tion software The vehicles come in capacities ranging from 500 pounds to 4000 pounds making them ideal for handling smaller loads and increased volumes without additional staff Features include multiple path programming a retractable towing pin remote communication and

Driverless trucks with voice directed picking

46 A P R I L 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

AGVs

MMH100401ProdFocus_ID 46 482010 113455 AM

MMH_1007_Productsindd 54 7610 156 PM

Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking This feature increases the volume to more than 35 units per minute It also includes energy-efficient electric motors quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control The unit can palletize cases trays bags or totes Automatic changeover is directed by the operator touch-screen panel For flexibility intelligent control accepts new or modified pallet layer and product configurations from authorized personnel with all operating parameters independently adjustable a-B-C Packaging Machine 800-237-5975 wwwabcpackagingcom

energy-efficient workstationThe electric workstation lift for palletizing offers quiet energy-efficient operation The area beneath is large and open for easy straddle stacker access to the platform For easy main-tenance standard 115-volt power units are rear mounted for access when the lift is in the down position The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated advance lifts 800-843-3625 wwwadvanceliftscom

robot works in tight spaces delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system Incorporating a large working enve-lope with small rotation radius and energy efficiency the robot works in tight space con-strictions at a high rate of throughput A 105-inch color touch-screen is included for human interface control (no laptop required) The system offers onboard diagnostics advanced

programming platform and up to 400 different pre-programmed recipes american-newlong 317-787-9421 wwwamerican-newlongcom

MMH1010_FocusOn_Prodindd 38 101210 159 PM

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

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PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

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C

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Y

CM

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CY

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classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

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Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

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To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

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Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

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ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

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MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

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L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

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To advertise or for more

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Jennifer Drevline

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MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

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As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 40: Modern Materials Handling - October 2010

Safety performance features included standardNew safety and performance features have been added standard to the supplierrsquos line of palletizers These include category 3 electrical circuits with dual-circuit safety interlocked door switches and light curtains at discharge To protect personnel from moving parts upper level guarding and a perimeter hand railing has been added to high-level palletizers Case entry guarding on both high-level and floor-level pallet-izers is configured as a moveable tunnel or an access door For simple addition or modification of patterns an easy-to-operate controls package provides for adjust-ment of PLC timers and variable frequency drive speeds plus generates production reports with enhanced alarm and troubleshooting support Columbia Machine 800-628-4065 wwwpalletizingcom

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 39

BLUE HAS NEVER BEEN SO GREEN

THE NATURAL CHOICE

Need to reduce your impact on the environment The CHEP Equipment Pooling System produces less solid waste and greenhouse gas while consuming less

total energy than other shipping options

Calculate your actual savings by shipping on CHEP

chepcomnaturalchoice

PACK EXPOBOOTH

E-5208RPA

PAVILION

Modular low-level in-feed case palletizingCompact low-level in-feed case palletizers offer modular con-struction and provide total automatic operation at speeds up to 280 layers per hour To save power an auto-shut down feature is included Ideal for limited space applications the in-feed and pallet handling systems have been separated from the main frame All electro-pneumatic operation eliminates container contamination for sanitary use Features include a heavy-duty open frame triple strand drag chain discharge conveyor case pusher bar with equally distributed pressure and PLC-controlled case orientation For simple operator interaction touch-screen technology gives access to system parameters Bastian Material Handling 314-432-2224 wwwbastiansolutionscom

Accurate gentle stacking of heavy bagsThe Paletpac 5000 high-capacity bag palletizer and stretch hood film packaging system gently stacks and secures bagged bulk mate-rials on pallets The machine stacks 5000 bulk material bags per hour It uses a bag flow distribution process that ensures low handling speeds and gentle handling on belt conveyors to reduce dust and prevent bag deformation To accommodate different stacking heights the stretch hood unit can be adjusted and includes an ultrasonic sensor to determine the film length required A formed hood is pulled over the complete pallet stack and is stretched to the bottom edge of the pallet to secure the stack The Beumer Group 732-560-8222 wwwbeumercom

Kawasaki robotic palletizers offered in North AmericaKawasaki robotic palletizersmdashwhich can palletize at rates up to 30 bags or cases per minute (1800 cycles per hour)mdashare now offered by a designated North American system integrator A direct coupled gearbox with AC servo motors directs the robot with absolute pulse encoders on all axes To program a layer or pallet pattern operators use a hand-held pendant with 64-inch liquid crystal color display and menu-driven interface Features include Ethernet and RS232 ports and a collision detection system Conveying Industries 303-373-2035 wwwconveyingindustriescom

MMH1010_FocusOn_Prodindd 39 101210 159 PM

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

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Find us on

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MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 41: Modern Materials Handling - October 2010

40 O c t O b e r 2 0 1 0 Modern Materials Handling mmhcom

Automatic turntable stretch wrapperThe economical WCA-Smart auto-matic turntable stretch wrapper combines two of the supplierrsquos previ-

ous products into one line standardizing tower and carriage for a reduction

in lead time and faster

product delivery

The new unit offers enclosed carriage chains an increase in stan-dard wrap height to 80 inches and optional wrap heights up to 116 inches An ergonomically friendly film loading carriage is mounted on the side for easy loading The system runs at a standard 12 revolu-tions per minute up to 22 optional-ly and has a spring loaded carriage gate split base for easy handling

42 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Motorized Storage amp Retrieval Solutions

Space Saving Ver cal Storage bull Bar Stock bull Spooled Products bull Tire Storage

bull Print Cylinders bull Rolled Goods bull Parts Storage

ldquoStorage amp Retrieval Solutions Since 1986rdquo

Contact Us Toll Free at 1-800-210-0141 or visit us online at wwwvidircom

AGV navigates tight spacesTransporting materials through tight narrow aisles is the Tite-Space BST AGV tugger with a min-imum turning radius of 175 inches The low-profile tugger includes a drive motor 24-Volt DC power sup-ply and guidance sensors It travels in a single direction along a mag-netic tape guide path at speeds up to 164 feet per minute The vehicle glides under stationary pushcarts

Chain hoists runs 1900 hours between servicingOffering extended service life up to 1900 hours the DC-Pro chain hoist runs longer between service inter-vals and general overhauls Many components are maintenance-free for up to 10 years Safety features include brakes that do not require adjustment and clutches that pro-vide protection against overload and slippage The hoist is offered in 275 to 11000 pound capacities with two different control configurations a pendant or the supplierrsquos control pendant for one-handed operation Demag Cranes amp Components 800-321-6560 wwwdemag-uscom Booth 2618

NA 2010 Cleveland

and three-year unlimited cycle war-ranty WulftecMJ Maillis 877-985-3832 wwwwulfteccom Booth 1209

engaging them by extending a catch pin into the cartrsquos connection interface then conveying them to loadunload points further along the path Creform 800-839-8823 wwwcreformcom Booths 1734 amp 1834

Collect data in harsh environmentsThe MX9 MX9CS and MX9HL ultra-rugged handheld computers offer data collection with an outdoor display with multiple scanning and imaging options Selections include back-lit keypads built-in GPS position-al location feature and 80211 abg WWAN and Bluetooth communica-tions The MX9 computer includes an IP67 rating and rugged packag-ing With low-temp batteries and built-in heater control the MX9CS is ideal for cold storage use The MX9HL complies with Class 1 Div 2 hazardous location environments LXE 800-664-4593 wwwlxecom Booth 1432

MMH100301ShowProds_IDindd 42 3102010 34218 PM

FOCUS ON Palletizers

Modular low-level palletizer handles multiple pack patterns pallet typesCapable of accommodating multiple pack patterns plant layouts and pallet types the heavy-duty medium speed LLP low-level in-feed palletizer handles more than 20 cases per minute Offered in either right- or left-hand parallel infeed configurations the modular unit can interface with side load or end load pallet dispensers A user-friendly human machine interface allows programming of additional pack patterns without field service For safety a framed guard door package safety circuits and muting light curtains are included Currie by Brenton 800-535-2730 wwwbrenton-engineeringcom

software generates robotic palletizing patternsRobotic palletizing systemsmdashincluding multi-lane palletizers layer pallet-izers lean palletizers bag palletizers and vacuum palletizer grippers for hard to handle productsmdashuse the ABB Pickmaster 5 software for a stan-dard but flexible palletizing solution The software allows the creation or modification of case sizes and pallet patterns To enable palletizing of multiple products within a single cell configurations range from one to five in-feeds and out-feeds Options include complete end-of-line automation with conveyors automatic guided vehicles and stretch wrapping QComp technologies 920-757-0775 wwwqcomptechcom

system palletizes directly to two stretch wrappers The stack and wrap palletizingstretch wrapping cell combines two or more lines into a centralized automated palletizing stretch wrapping station The integrated equipment builds the unit load on the stretch wrapper for more efficient handling of lightweight unstable loads in less floor space Incorporated are a robotic arm two stretch wrappers automatic pallet dispenser and conveyor system to deliver empty pallets to each stretch wrapper Once a predetermined number of cases are loaded onto the first pallet the first wrapper applies film to stabilize the load layers while the robotic arm builds a load on the second stretch wrapper The alternating process repeats until the load is complete and product is discharged to a conveyor transfer system The system can handle two different products simultaneously for high throughput schneider Packaging equipment 315-676-3035 wwwschneiderequipcom lantech 800-866-0322 wwwlantechcom

MMH1010_FocusOn_Prodindd 40 101210 159 PM

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

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SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

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MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 42: Modern Materials Handling - October 2010

mmhcom MODERN MATERIALS HANDLING O C T O B E R 2 0 1 0 41

PACK EXPOBOOTH

E-5208RPA

PAVILION

THE SIMPLE CHOICE

BLUE HAS NEVER BEEN SO EASY

Saving time Saving moneyInnovative solutions from CHEP help you do both

See how tools like our online portal Portfolio+Plus can streamline your administrative activities

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Robotic arm retrofit creates hybrid palletizerAlvey robotic arm retrofits for existing in-line case palletizers create a hybrid palletizer that combines flexibility and repeatability with the speed and reliability of conven-tional layer deposition The solution yields gentler positioning and rotation of product automatic line changeovers pattern changing flexibility and extended life at a lower cost than a new installation Completed on-site the retrofit removes the slat divider and existing case turners and replaces them with one or more robotic arms for pattern forming Also included are end-of-arm tooling operator interface terminal screens in-feed conveyor and PLC programming With quick product reconfiguration and instant line changeovers systems achieve packaging rates of more than 100 cases per minute Intelligrated 513-881-5239 wwwintelligratedcom

Palletizer delivers product changeover in less than 60 secondsThe master 3500 high-level palletizer features a servo-controlled layer pusher and pallet lift motors advanced machine diagnos-tics and a totally integrated Allen-Bradley control architecture The machine is economical and reliable and it also includes enhanced ergonomics for ease of use Recipe-driven product changeover can be accomplished in less than 1 minute Thiele Technologies 612-782-1200 wwwthieletechcom

Hybrid robot palletizer for bags cases and traysRoboTier palletizers integrate a Fanuc M-710 robot for pick and place operations onto a standard layer-conditioning apron The unit supports product from the bottom allowing

high-speed robot motion and handling security Loose spread placement on the apron increases robot speed and accom-modates greater product variability Once a layer is completed four-sided clamps center the layer on the pallet preparing the load for optional concurrent stretch wrapping For easy cre-ation of new patterns without PLC or robot programming load building software is included and accessed with a touch-screen control TopTier 503-353-7388 wwwtoptiercom

Palletize 108 cases onto two full pallets per minute Constructed entirely of stainless steel the case palletizing system handles plastic and wood pallets The system palletizes two pallets per minute each holding nine stacks of cases stacked six high or 54 cases per pallet Ideal for wash-down use the system includes an electric-powered pallet dispenser and an empty pal-let pusher that transfers pallets into the stack loading zone under the transfer plate The hydraulic palletizing unit features an in-feed conveyor with stack stop pan style drive in-feed stack transfer pusher with load zone transfer plate and full pallet loading The system is protected by a safety fence with light curtains Westfalia Deam Systems 800-673-2522 wwwwestfaliausacom

MMH1010_FocusOn_Prodindd 41 101210 200 PM

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

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SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

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MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

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SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 43: Modern Materials Handling - October 2010

ldquo We eliminated materials

handling inefficiencies

associated with using third-

party warehousing and we

have a better cost structure

across the network than we

did before Braseltonrdquo

ndash Mike Fernstrom director of DC operations

42S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Petcostrengthensthe network

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

Getty ImagesGary Payne

MMH1010WDC_supplementindd 42 101310 940 AM

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

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MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 44: Modern Materials Handling - October 2010

mmhcom Modern Materials Handling O c t O b e r 2 0 1 0 43s

With more than 76 million cats 62 mil-lion dogs and 9 mil-lion aquarium own-ers Americans love

pets Over the past 45 years Petco Animal Supplies has built a national brand as the place where pets and their owners go helping more animals to live long and happy lives Today the San Diego-based retailer has a foot-print in all 50 states with more than 1000 stores and a growing e-com-merce business

To support the companyrsquos growth Petco partnered with a supplier (TGW Systems wwwtgwsystemscom) to design and implement the materials handling system in its new 506000-square-foot distribution cen-ter in Braselton Ga The facility which went live in June 2008 services 237

stores in 13 states in the Southeastern and Southwestern United States

According to Mike Fernstrom direc-tor of DC operations the new Southeast location coupled with the capabilities of the new system has allowed Petco to reduce its handling costs bolster its green transportation initiatives and strengthen its overall distribution net-workmdashall while providing room to grow

First the DCrsquos new system is flexible enough to handle a variety of productsmdasheverything from accessories that fit eas-ily into a carton and can be automatically conveyed and sorted to non-conveyables like pallets of dog food animal crates and furniture It can also process an estimated 5 million units per month for store replenishment as well as direct-to-consumer orders from a 70000-square-foot area dedicated to piece picking for dotcom fulfillment

Second locating the new distribu-tion center in the Southeast delivered a couple additional strategic logistics benefits During 2008 the year the facility went live Petco drivers trav-eled 900000 fewer miles saving 135000 gallons of diesel furthering the retailerrsquos ldquogoing greenrdquo initiative

And by being closer to the markets it serves the project drove further transportation efficiencies because Petco was no able to convert over-the-road truck routes to southern Florida and Texas to intermodal

ldquoNot only have we reduced our cost per case but the cost to operate our overall network has gone down as a direct result of the capacity we added in Braseltonrdquo says Fernstrom ldquoWe elimi-nated materials handling inefficiencies associated with using third-party ware-housing and we have a better cost

Feature pho

tos b

y Dan W

atts

By Bob trebilcock Executive Editor

With its new dC and materials handling system the pet retailer has reduced its handling costs bolstered its green transportation initiatives and strengthened its overall distribution networkmdashall while providing room to grow

the new 506000 square foot distribution center in Braselton ga

MMH1010WDC_supplementindd 43 101310 940 AM

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

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SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 45: Modern Materials Handling - October 2010

structure across the network than we did before Braseltonrdquo

Adding cApAcity According to Fernstrom Petcorsquos con-tinued growth was the driving factor behind the new distribution center The retailer currently operates a net-work of 10 distribution centers Along with the new Braselton DC Petco has three other full assortment distribution centers including Monroe NJ Joliet Ill and a West Coast operation

The remaining regional facilities are smaller in size ranging from 50000 to 90000 square feet are located close to the markets they serve and stock fast-moving items like pet food and cat litter for quick replenishment

Prior to building the facility in Bra-selton stores in the Southeast and Southwest were serviced by the New Jersey and Illinois facilities All three full assortment DCs were filling dotcom orders as well ldquoAs our business grew we ran out of spacerdquo says Fern-strom ldquoTo keep up with growth we were using public warehousing for our year-round surplus storage and 3PLs for seasonal businessrdquo

That was inefficient and expensive In 2007 Petco conducted a network

study and concluded that it needed a full assortment DC in the Southeast Beyond getting a footprint in Georgia that would optimize the network Petco had several goals for the new facility

One was to leverage the invest-ment in materials handling automation and get volume out of the building by moving the growing dotcom business to Georgia ldquoWe were doing direct-to-consumer order fulfillment from all three of our full assortment DCsrdquo says Fernstrom ldquoWe decided to consolidate that business in the new facility and operate Joliet as a contingency opera-

tion in case Braselton has a maintenance issuerdquo

Another key require-ment was to install break pack or split case pick-ing modules and picking methodologies to build store-ready mixed SKU pallets configured by stocking zones within the stores they were going to be delivered to ldquoWe did not have pick modules in our other buildings so the totes had a mix of prod-ucts that had to be sorted in the store before the product could go on the

shelfrdquo says Fernstrom ldquoWith the new system we can pack totes and build pallets with products that are specific to a zone or departments in a store That saves a lot of time on the other endrdquo

A final objective was to optimize Petcorsquos transportation network By being closer to the stores it serves than New Jersey and Illinois the retailer was able to shave thousands of miles from its delivery routes The transportation department was even able to save more miles by converting some truck deliver-ies to rail

Bringing integrAtion to the tABle One of the challenges of the new facility was the aggressive timeline for the proj-ect The design process began in Octo-ber of 2007 the implementation began in April 2008 with the first receipts coming in July and the first deliveries leaving the buildings in August

ldquoOnce we made the decision to build a facility that would take us into the next generation we wanted to get the capacity online before the next holiday seasonrdquo says Fernstrom ldquoWe were han-dling product multiple times either in external buildings or because we had to consolidate our reserve storage on a

Warehouse amp dc

Petco installed break pack or split case picking modules and picking methodologies like ring scanning to build store-ready mixed SKU pallets by stocking zones in a store

The new location in Georgia is closer to markets in the Southeast and Southwest saving 900000 transportation miles a year

44S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

MMH1010WDC_supplementindd 44 101310 940 AM

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 46: Modern Materials Handling - October 2010

Interlake Mecalux is a global leader in the storage systems market In March 2009 Mecalux formalized the asset acquisition of the companies UFC Interlake Holding Company United Fixtures Company Inc and Interlake Mate-rial Handling Inc The US operation expanded to six produc-tion plants which allow the unified company now known as Interlake Mecalux Inc to effectively cover the entire US and Canadian territories

As one of the leading manufacturers Interlake Mecalux offers its customers the broadest array of storage products in the world Along with examining customer needs from every angle and designing a system that is efficient cost-effective and built to last Interlake Mecalux provides a comprehensive turn-key answer to todayrsquos complex material handling and logistics needs Backed by an impressive suite of products and services offerings Interlake Mecalux is stronger than ever and dedicated to exceeding customersrsquo expectations by anticipating their needs and delivering unmatched solutions and service

With more than 15 million square feet of production space Interlake Mecalux is by far the largest supplier of storage

rack in North America We use the highest quality raw materials which are certified to meet our stringent specifications All weld operations are controlled through advanced robotics or performed by welders certified to AWS Standards We then use a combination of powder coating and Cataphoresis paint systems to ensure an aesthetically pleasing durable finish The result the highest quality products in the industry

The primary markets served by Interlake Mecalux products and services include companies which operate full-scale distribution centers warehouses of all sizes manufacturing facilities and archive and record storage environments Our growth and development is based on the expansion of the sales distribution networks investment in Research amp Devel-opment and our automated warehouse division Since our foundation more than 40 years ago our approach has been an unyielding commitment to quality innovation and customer satisfaction

Serving North America from seven strategetic locations Chicago Sumter Tijuana Matamoros Dallas San Diego Pontiac

Tel 8776322589 | wwwinterlakemecaluxcom | Email infointerlakemecaluxcom

MMH1010_Adsindd 45 101210 1053 AM

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 47: Modern Materials Handling - October 2010

46S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

daily basis just to make room We had to get this donerdquo

According to Fernstrom thatrsquos where the system supplier played a vital role Although Petco was responsible for the overall design of the facility he says its system provider was a strong partner throughout that process The supplier was also responsible for manufacturing the conveyor racking mezzanines and sortation equipment and integrating the warehouse control system and pick-ing technologies

A key component to the overall design was the narrow belt sorter that can sort 120 cartons per minute with an extremely mixed product size The sorter is 600 feet long with 18 diverts With its modular design the sorter will allow Petco to easily add new divert lanes in the future as business expands

ldquoThe narrow belt sorter gave us slid-ing shoe capabilities but with a faster implementation time and a much lower costrdquo says Russell Pace sales

manager for TGWrsquos integrated systems group With just three 15-horsepower motors required to drive the system the sorter is also 30 more energy effi-cient than a sliding shoe sorter with comparable throughput

Another key feature is a cartoniza-tion function within the warehouse con-trol system (WCS) The WCS profiles orders to determine how many cartons will be required to complete each order

A zone skipping feature allows the facility to route a tote anywhere in the break pack piece picking modules to make sure that the right SKUs are picked to a tote to meet the goal for store-ready totes and pallets ldquoThat functionality was absolutely the right thing to do in order to meet that goalrdquo says Fernstrom

Finally Petco took advantage of a variety of picking technologies all directed by the facilityrsquos warehouse management system Piece picking in the three-level break pack mezzanine for instance is directed by pick-to-light Associates in the three full-case

pick modules use voice technology to work in a hands freeeyes free environ-ment RF directs some of the picking in the dotcom area

To keep the system up and running the system supplier provides ongoing software maintenance for the conveyor and pick-to-light systems ldquoOur techni-cians can dial into the system for 247 supportrdquo says Pace

HoW it WorkS The Braselton facility brings together a variety of technologies that minimize handling and reduce costs starting at the receiving dock

There Petco receives against a pur-chase order Full pallets of a single SKU like dog food are ready for putaway once a UPC barcode has been scanned and validated An overseas shipping con-tainer on the other hand may have product from several dozen POs and may contain hundreds of SKUs Those products will be sorted and palletized by SKU The WMS will then create

Petcorsquos Braselton Ga DC System snapshot the 506000-square-fOOt braseltOn distributiOn center brOught together an innovative design and energy saving automated materials handling equipment from TGW Systems to handle store replenishment in the Southeastern United States as well as direct-to-consumer dotcom fulfillment

The facility manages an estimated 13000 SKUs and handles an estimated 5 million units per month Features of the system include

Break pack piece pick moduleThe break pack system is served by a conveyor system designed to route totes to active pick zones at a rate of 1500 totes per hour

24 pick zones bull 8 zones per level bull 3 levels high

12 carton flow bays per pick zone bull 4 shelf levels per bay bull 6 SKUs per shelf level

2 static shelving units per pick zone bull 5 shelf levels per unit bull 6 SKUs per shelf level

Three full case pick modulesIn total the full case pick module area features 1584 static locations and 1584 pallet flow locations for a total of 3168 full case locations The system supports throughput of 1800 cases per hour per module or a total of 5400 cases per hour

bull 88 bays per level bull 3 levels high bull 2 pallet positions per bay bull 6 static positions per bay on the floor level only

Shipping sorterThe induction scanning and sortation system supports throughput of up to 120 cartons per minute7200 per hour

bull Automated merge of 4 module accumulation lines and a sorter recirculation line

bull 16 dedicated shipping lanes bull 1 dotcom sort lane bull 1 exceptions lane

DotcomThe 70000-square-foot dotcom area supports Petcorsquos growing direct-to-consumer business and features

bull 8 sort lanes with a put-to-order pack out systembull dunnage and taping area bull parcel scale and manifesting

MMH1010WDC_supplementindd 46 101310 940 AM

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 48: Modern Materials Handling - October 2010

View Our New Interactive Ad in MODERNrsquos Digital Edition

MM1006 ppxx Dehncoindd 1 6910 1212 PMMMH1010_Adsindd 47 101210 1053 AM

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 49: Modern Materials Handling - October 2010

48S O c t O b e r 2 0 1 0 Modern MaterialS Handling mmhcom

a license plate bar code label that is applied to a pallet and scanned

Lift truck operators are directed by the WMS to store pallets in single deep pallet rack The WMS also directs replenishment Full case modules with two-deep pallet rack are replenished by a reach truck operator while break pack modules are replenished from a man-aboard truck Orders for store replenish-ment drop from an order management system into the WMS The system then creates waves of orders to be picked for a group of stores for that day

In the full case pick zone an asso-ciate receives a stack of labels that are sorted in bin sequence The associate applies a label to cases as theyrsquore picked and then places the cases on the take-away belt conveyor After the bar code is automatically read at the sorter induc-tion point a carton is diverted to a ship-ping lane There it will be palletized stretch-wrapped and staged for delivery

In the break pack picking modules the associate starts the picking process by applying and scanning a label on a tote The pick-to-light system identi-fies the items and quantities for each pick in that associatersquos area Once the picks have been completed for that tote itrsquos placed on a takeaway conveyor and routed to the next pick zone After the final pick the tote is closed and conveyed to an induction point for the sorter

After the label is scanned the tote is sorted to the right shipping lane where it will be palletized stretch-wrapped and staged for delivery

Non-conveyables are picked by order selectors using pallet jacks with 96-inch forks Wearing voice headsets they are directed to a pick location and told by the system how many pal-lets to pick They confirm the pick by speaking a check digit into their head-set Pallets are then delivered to the

stretch wrapper where they are wrapped and staged for delivery

Items for dotcom orders are picked in a break pack module and are then conveyed and sorted to a pack station for direct-to-con-sumer orders There multi-line orders are packed together into a single shipping container Dun-nage is added and the cartons are taped shut for shipment

Dotcom orders may also include items from the full case area as well as non-conveyables like pet food animal cages and furniture Those are delivered to the shipping area where they are manifested with the appropriate shipping paper and are shipped out

Fine tuning One year after the system went live the system provider per-formed a facility assessment to insure that the system was meet-ing its goals The result Petco discovered that some new prod-ucts werenrsquot within the original

design specifications Instead of being read by the

bar code scanner they were being diverted as misreads to a quality check station where they were manu-ally audited The system supplier installed new photo eyes to pick up the new products In addition Petco worked with the provider to reduce the number of pallet sizes it was han-dling from three to two to drive fur-ther efficiencies

Approaching the two-year anniver-sary of going live Fernstrom says the system has been a success ldquoWe have been able to sort totes by the stock-ing zone in the store from day onerdquo he says ldquoSince then wersquove implemented that same process in our other DCs and are able to do that across the companyrdquo

Most important of all Petco is bring-ing down its handling costs while pro-viding room to grow M

Warehouse amp DC Special Supplement

ADVANCED SITE SELECTION

A high-speed conveyor and narrow belt shipping sorter handles 120 cartons per minute with mixed sized products

MMH1010WDC_supplementindd 48 101310 940 AM

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 50: Modern Materials Handling - October 2010

INNOVATION

EDUCATION

NETWORKING

SOLUTIONS

YOUR ONE EVENT FOR

From March 21-24 2011 the material handling and logistics industry will showcase the latest manufacturing distribution and supply chain solutions at ProMat 2011

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions Choose from 80 educational sessions that deliver valuable insights into the latest trends technologies and innovations

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you

bull Streamline your operations and improve visibilitybull Maximize effi ciency and fl exibilitybull Cut costsbull Speed time to marketbull Reduce your carbon footprint

Register Today For ProMat 2011Find free registration detailed exhibitor information educational session details show news and your customized My ProMat Show Planner at wwwProMatShowcom or call 800-446-2622 or 704-676-1186

wwwProMatShowcomSponsored by

Collocated with ProMat 2011

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORKreg

Find us on

Job9015 General Modern Material Handling MHIAProMat API78647 1010

9015-MHIA ProMatAttendeeAdindd 1 9710 1037 AMMMH1010_Adsindd 49 101210 1053 AM

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 51: Modern Materials Handling - October 2010

MODERN 60 Seconds with

Arthur ldquoMacrdquo Barrett Jr

Inventor of the ldquoGuide-O-Maticrdquo

Modern Do you remember the development of the Guide-O-Matic

Kellogg I do The vehicle was patented in 1958 but he was working on it as early as 1956 As a very young girl I spent my Saturdays at the plant as the other half of the RampD team It began as a remote-controlled vehicle guided by wires overhead Later he put the wire guides in the floor

Modern Tell us a little about your father

Kellogg He came from a family of tinkerers His father owned a book bindery in Chicago If he saw a piece of equipment he would try to improve on it That led him to start Barrett-Cravens to build pallet

trucks (Note The lift truck business was subsequently sold and today is part of Nissan Forklift in Marengo Ill) My father was much the same way He was an engineer and he was naturally interested in making things work better He once told my mother that if a new maid didnrsquot work out he could replace her with a robot and he meant it

Modern Do you know what led him to invent the AGV

Kellogg The original Guide-O-Matic was an attempt to automate some of the processes in my grandfatherrsquos bindery It didnrsquot make sense to my father to have 10 lift truck operators for 10 machines when you could program one machine to pull a series of carts and stop automatically wherever you needed the carts

Modern Irsquove heard your father invented an automated lawn mower

Kellogg He called it the Mowbot We lived in the country and had a lot of acreage He put a huge antenna that could receive a remote control signal on our gang mower Hersquod come home from work and say I think Irsquoll mow the lawn Then hersquod sit down on the porch push a button and read the newspaper It was just for fun I think one of our neighbors got concerned and called the police

Modern Did your father think of himself as a pioneer

Kellogg I doubt it But he did have a passion for the industry and a passion for innovation He saw them as improving the quality of life

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking for the plant that built AGVs in Northbrook Ill From the left Joan Barrett Kellogg Mac Barrett and his parents Mrs and Mr Arthur M Barrett Sr

Pho

tog

rap

h co

utes

y o

f B

arre

tt fa

mily

The Barrett family at the ground breaking

Mac Barrett credited as the father of the automatic guided vehicle (AGV) passed away in August at the age of 89 Modern talked to his daughter Joan Barrett Kellogg about her father and the develop-ment of the ldquoGuide-O-Maticrdquo the first wire-guided AGV One of the original Guide-O-Matic vehicles can still be seen in Grand Rapids Mich at the offices of Savant Automation (wwwagvsystemscom) the succes-sor to Barrett Electronics

50 O C T O B E R 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

MMH1010_60Secondsindd 50 101310 1052 AM

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 52: Modern Materials Handling - October 2010

classifiedrecruitment

46 M A R C H 2 0 1 0 MODERN MATERIALS HANDLING mmhcom

Label Holders

Ergonomic Holster Systems

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

6190-K Fairmount Ave San Diego CA 92120

info800-338-8759 or 619-280-9992

reg

Holster YourSide Arm

or a slingerright or left

classifiedrecruitment

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

WHEN YOU DONrsquoT ADVERTISE A

TERRIBLE THING HAPPENS

NOTHING

Racks

Accessorize for faster product mix swaps

New slotting accessories for the supplierrsquos SelecDeck carton flow sys-tem enable fast cost-effective prod-uct mix changes Offerings include drop-in lane dividers that fit into slots along the load side and permit cartons to be added changed and sorted by size and SKU To eliminate adhesive labels a sliding label holder can be placed anywhere along the front of the case flow bed for hassle-free reprofiling Additionally the SelecDeck system retrofits existing structural roll-formed racks with-out replacing shelf beams Frazier Industrial 800-614-4162 wwwfraziercom

Steel axle carton flow tracksCarton Trax steel axle carton flow track features abuse-resistant 1125-inch dia-meter polyethyl-ene rollers and chromate-coated steel axles that are free-floating to prevent binding for durable smooth operation The heavy-duty tracks incorporate a specially engineered steel axle tooth for close wheel placement that enhances reliability For carton support the wheels are placed on 15 inch centers The grav-ity-driven tracks include durable galvanized side channels making them ideal for freezer and food stor-age applications UNARCO Material Handling 800-862-7261 wwwunarcorackcom

Racking resists earthquakes

Offering greater lateral stability than the supplierrsquos standard pallet rack the PLUS rack is ideal for areas where seismic activity or other severe conditions are likely The rackrsquos beam end connectors feature four prongs to create a tighter connection with more surface area between the beam and the upright post Beams are welded 3 inches down from the top of the connector to evenly distribute loads across all four prongs To pre-vent accidental dislodging all beams have a beam locking key Upright frames offer heavy-duty 35-square-inch 0325-inch thick footplates with four anchoring holes Standard frame heights range from 48 to 240 inches Penco Products 800-562-1000 wwwpencoproductscom

Customized push back rack systemsPush back high-den-sity storage rack permits selectivity and dense storage making it ideal for storage of multiple SKUs and mul-tiple pallets of individual SKUs The system includes an integrated cart system mounted on rails in the rack structure at a slight pitch Pallets are placed on the carts as many as six-deep per storage lane Each racking system is custom-configured to match specific pallet and load size width depth and height Elite Storage Solutions 508-230-5755 wwwelitestoragesolutionscom

MMH100301ShowProds_IDindd 46 3102010 35218 PM

SUPERIOR BANDS

2 PLY THREAD DESIGN

COVERELASTIC COREYARN

8002272906 Video Conferencingsuperiorbandsbellsouthnet

QUICK CONNECT

TWISTED O-RINGS

NO TOOLS REQUIRED

wwwsuperiorbandscom

C

M

Y

CM

MY

CY

CMY

K

classifiedrecruitment

Label Holders Load Transfer Systems

Career Opportunities

LabelHolders

Donrsquot Cost - They Pay

800-242-3919wwwaignerindexcom holdexfrontiernetnet

VPDistribution Systems Sales Engineers Engineering Manager VPLogistics VPSales DirMarketing

Auction

To advertise or for more information

please contactJennifer Drevline

847-223-5225 ext 11jenniferdcaseyrepscom

mmh100401_cls 2 462010 121452 PM

ExEcutivE OfficEs111 Speen StreetFramingham ma 01701508-663-1500

Brian ceraolopublisher bceraoloehpubcom

Kelly Jonesproduction managerkjonesehpubcom

charles tannerCirculation managerctannerehpubcom

salEs OfficEsCt De FL ma mD me mi nh nJ nY Oh pa ri Vt WV eastern Cansteve Mccoy national Sales Director 508-261-1120 Fax 508-261-1121 smccoyehpubcom

ia iL in KS mn mO nD ne SD Wi Central CanBob casey District Sales Director 847-223-5225 Fax 847-223-5281 bobccaseyrepscom

ar aZ Ca CO iD La mS mt nV OK Or tX Ut Va Wa WY Western CanPaul Zampitella District Sales Director 508-663-1500 x307 Fax 877-330-7436 pzampitellaehpubcom

aL DC KY FL ga nC pa SC tn Va WV Greg Bolen District Sales Director 704-875-7977 Fax 866-680-5930 gregbolenthebolengroupnet

WEB OPEratiOnsclive PurchaseDirector Web Operations cpurchaseehpubcom

DirEctOr Of OnlinE salEsPaul Zampitella508-663-1500 x307 pzampitellaehpubcom

custOM articlE rEPrintsreprint management Servicesthe YgS group (800)290-5460 x100 modernmaterialstheygsgroupcom

MaGaZinE suBscriPtiOnsStart renew or update your Free magazine subscription at wwwmmhcomsubscribeContact customer service atWeb wwwmmhcomsubscribeEmail mmhsubsehpubcomPh 1-800-315-1578 x294Mail peerless media pO Box 1496 Framingham ma 01701

enEWslEttEr suBscriPtiOnsSign up or manage your Free enewsletter subscriptions at wwwmmhcomenewsletters

Business staff

Bumpy Rides

L O G I S T E R R A I N C

Secure YourTerminal and

with a LOGISTERRAtruck-mount Holder

infologisterracom bull wwwlogisterracom619-280-9992

reg

Holster YourSide Arm

bull Proven productsbull Years in servicebull Deployed worldwidebull Made in USA

or a slingerright or left

Ergonomic Holster systems

label Holders

twisted O-rings

career Opportunities

To advertise or for more

information please contact

Jennifer Drevline

847-223-5225 ext 11

jenniferdcaseyrepscom

MMH1010_Classifiedindd 3 101210 346 PM

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells
Page 53: Modern Materials Handling - October 2010

bull FirmaLoadtrade bulk bag carriers make moving and storing bulk bags cleaner easier and more stable

bull FirmaCoretrade lightweight carriers are built specially for one-way shipping of lightweight products for less

bull FirmaDecktrade corrugated carriers are engineered to provide strength to exactly fi t your products and processes

sonocotranspackcom888875-8754

As your sustainability commitments grow the inherent weaknesses of conventional pallets become unacceptable Learn more about all the innovations in Sonocorsquos new Firma line of carriers click or call

Sure conventional pallets do the job Just not very well Th ey damage your product jam your material handling systems cause injuries host insects and create disposal headaches If you ever wanted a better way this is it Firma brand unitized load carriers from Sonoco can reduce your costs meet global shipping challenges and help you be better stewards of the earthrsquos resources

bull FirmaGuardtrade components make wood pallets more protective durable and longer lasting

bull FirmaMaxtrade plastic carriers (made entirely from recycled plastics) off er stronger stiff er slip-resistant transit

One-size-fi ts-all pallets have come

to a dead end

Sure conventional pallets dJust noottt vveerryy welllllllll ThTh ey damage your product jam your

MM1007 ppxx Sonocoindd 1 61410 13951 PMMMH1010_Adsindd 50 101210 1053 AM

  • Contents
  • COVER STORY
    • SYSTEM REPORT
      • Best in class
        • Automatic guided vehicles streamline operations
          • FEATURES
            • PRODUCTIVITY SOLUTION
              • Tilt toward safety and productivity
                • SPECIAL REPORT
                  • Top 20 automatic data capture suppliers
                    • INFORMATION MANAGEMENT
                      • In sync Data capture and mobile computing
                        • EQUIPMENT REPORT
                          • Carousels Turning picking into productivity
                              • DEPARTMENTS ampamp COLUMNS
                                • Upfront
                                • This Month in Modern
                                • Lift Truck Tips Level the playing field
                                • Focus On Palletizers
                                • Supplement WarehousesDCs
                                • 60 seconds with
                                  • NEWS
                                    • MHIA Growth is back
                                    • HighJump to acquire TrueCommerce
                                    • Final thoughts on Supply Chain Reset
                                    • Industrial real estate market making progress challenges remain
                                    • Crown unveils 20 electric lift trucks to operate with fuel cells