Material Handling Experts


Information on the products and techniques to better store, handle, and move products in your facility.

Inspecting Your Pallet Racks for Damage

April 1, 2012

drive in rackWhen was the last time you had your pallet rack inspected?

Every operation that operates mechanical lifting equipment is required by the  Health and Safety at Work Act 1974 to inspect and document the safety of their racking systems. It’s the most common storage equipment in the world, and an inspection can not only help you comply with the law – it can help you see other issues in your warehouse. We have created a checklist of items to check and ways to check them.

Posted in Docks & Shipping, Industrial Shelving, Material Handling, Mezzanines, Pallet Rack, Safety & Ergonomics, Warehousing| No Comments »

How to Benchmark Your Warehouse

March 26, 2012

Warehouse measurement

Everyone likes to see how they’re doing vs. their industry peers.  This isn’t just a natural urge to compare yourself, it’s a vital part of doing business.

Benchmarking, at the heart of it, is comparing your performance to others like you. You look at your business processes and outcomes, and how they stack up to the performance metrics of industry leaders, your peers, and the best from similar operations. In warehousing, it is particularly important to understand where you are, and where you could be with reconfigurations, tweaks, and innovations that others are using to improve their numbers.  What do you specifically measure? Typically this can include quality, cost, and time. Specifically, it can get much more complex.

At the end it helps you understand the success of your peers and how you can reproduce that success.

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Visitors to your operation: how to make them safer

February 29, 2012

Are your warehouse visitors paying attention?

Safety is always a concern for industrial operations, but visitors take the dangers to another level.

In a fast-paced distribution center, there is plenty of forklift traffic, moving conveyors, packing machines, carousels, and dock doors. Same with manufacturing; you have all kinds of production machinery, welding (human and robotic), and heavy material being handled, stacked, or processed, along with the forklifts and other handling equipment. It’s hard enough to keep your own people – the ones who should know the lay of the land – safe in these environments. But what about visitors who haven’t had the benefit of your safety training and the situational awareness that your employees develop over time?

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Posted in Conveyor, Cross Docking, Manufacturing, Material Handling, Order Picking & Fulfillment, Safety & Ergonomics, Warehousing| No Comments »

Ways to Reduce Product Damage in Your Warehouse

February 16, 2012

crushed box
In warehouse & manufacturing operations, things get broken. They break in a number of ways, and it’s expensive. You’ve probably seen product broken or damaged in amazing and improbable ways  if you’ve been in this business for any length of time.

We had a client once buy a bunch of mismatched, used industrial shelving (not from us), only to see it collapse and dump thousands of tiny aircraft components on the floor. It had to be swept up and discarded since it was all mixed up and visually impossible to sort.

Those are extraordinary examples, but everyday inventory damage that cost “only” a few hundred or thousand dollars can savage your bottom line.

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Posted in Industrial Shelving, Material Handling, Order Picking & Fulfillment, Safety & Ergonomics, Warehousing| No Comments »

To-Do’s For Moving Your Warehouse

February 7, 2012

warehouse reconfiguration

Over the past four decades, we’ve seen plenty of operations move. We’ve installed entirely new conveyor systems into functioning operations without disturbing the flow of existing work. We’ve seen companies pick up an entire distribution operation and move it across two hundred feet of parking lot into another building. It’s not new territory for us, and probably if you have managed a manufacturing or warehousing operation long, it’s not for you either.

Like moving your personal household, it’s chaotic, fast-paced, inconvenient and usually painful – in fact more painful than a personal move because there are so many moving parts, so many ways to get it wrong. How can you reduce the pain and get back into gear as fast as possible?

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Posted in Conveyor, Docks & Shipping, Industrial Shelving, Material Handling, Mezzanines, Order Picking & Fulfillment, Safety & Ergonomics, Warehousing| No Comments »

Justifying AisleCop Forklift Safety Gate Systems

January 13, 2012

AisleCop warehouse pedestrian safety systemWe see two kinds of operations that have shown interest in, or implemented an AisleCop® forklift safety gate system. The first are those companies who have defined traffic plans and are looking to prevent possible accidents in high-risk, limited-visibility, or heavy-traffic aisles. They foresee potential accidents and are taking measures to prevent them. The second kind are companies who have had an incident, or a near-miss.

In both cases, the question has been “how can I justify this system?”

Aside from the fact that it could help save a life, or help prevent horrific injuries (the only kind that a forklift-pedestrian accidents seem to produce), AisleCop® can also save money in a variety of ways.

We have created a document, free for download, that you can use if you’re pitching a safety system to your management. It’s a short, but informative read.

Check it out here: “AisleCop®  return on investment” (PDF file)

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Posted in Manufacturing, Material Handling, News, Pallet Rack, ROI, Safety & Ergonomics, Warehousing| No Comments »

The 5S Approach to Workcells & Workstations

January 4, 2012

workstation with 5S implementation

Based on 5 Japanese words that begin with ‘S’, the 5S Philosophy hones in on effective work place organization and standardized work procedures. When correctly implemented, it reduces waste, increases efficiency, and overall work quality. You’ll also have a safer, more effective operation and employees who are more checked in than they were before. It simplifies work flow and helps you find inefficiency.  You may see things like empty flow racks, needless processes, over stocking, redundant operations,  looming maintenance problems, and more.

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Posted in Docks & Shipping, Industrial Shelving, Manufacturing, Material Handling, Order Picking & Fulfillment, Safety & Ergonomics, Space Saving, Supply Chain, Sustainability, Warehousing, Workbenches & Stations| No Comments »

Ideas to Keep Your Warehouse Clean

January 3, 2012

One easy way to gauge a warehouse or manufacturing plant ‘s effectiveness is to check how clean it is. Cleaner facilities are more productive, tend to be safer, and tend to be more organized.

Whether your facility features gleaming floors or just keeps debris from packaging materials, pallets, and accumulated junk under control, being cleaner is well worth the time investment. People who work in a disorganized facility where things just feel sloppy won’t work as well. They may make more errors. They won’t have pride in the operation.  An inch of dust on rack beams or beneath conveyor legs sends a message to workers. You don’t need a sparkling facility with floors so clean you could have lunch on them, but a well-lit, organized, pleasant place to work can be helpful in employee attitudes and retention.

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Posted in Docks & Shipping, Industrial Shelving, Manufacturing, Material Handling, Order Picking & Fulfillment, Pallet Rack, Safety & Ergonomics, Warehousing| 5 Comments »

A Different Sort of Sorter

December 2, 2011

Sortation systems in distribution is application driven – typically we are talking about order fulfillment (retail, wave pre-sorting, inbound putaway sorts), shipping (end of line carrier sortation, ship to stores), and returns. Traditional sweep sorters, cross-belt, narrow slat & shoe, or belt sorters are often thought of as “for the big guys” in large operations. SpanTech’s new TranSorter is  different, and it’s rolling out at Modex 2012. A sneak peek video below:

The TranSorter is built for hard to sort items, such as fragile items that require different handling. It’s good for ultra-lightweight items, poly bags, etc.  It’s scalable, flexible, and affordable due to truly modular design, a world of layout possibilities, and competitive pricing. It can also deploy quickly, with 6-8 week delivery times and a couple days installation time. If you’re planning to attend Modex, check it out.

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Posted in Automation, Conveyor, Cross Docking, Docks & Shipping, Material Handling, News, Order Picking & Fulfillment, Pallet Rack, Warehousing| No Comments »

How the Movies Get Material Handling Wrong

November 15, 2011

Mateial handling movies

If you are in the warehousing or material handling industry, you’ll find yourself identifying warehouse and handling equipment in movies or television shows quite often. Many of us have seen, for instance, the NFL graphics of a large distribution system used on Fox network for years. I’ve pointed out Hytrol conveyors in movies to my wife for years, to the point where she says it first when she sees it.

For fun, we have put together a list of the more famous scenes in entertainment history involving material handling equipment, and how it could have been done better.

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Posted in Automation, Conveyor, Industrial Shelving, Lifts, News, Pallet Rack, Warehousing| No Comments »