Scott Stone | Warehousing Insights | Material Handling Systems - Part 12
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Warehouse Automation Risks to Avoid

October 15, 2020

illustration of conveyor and robotic systems integration
Automation can work wonders. It reduces costs, increases throughput, curbs errors and increases safety. The costs of automation are declining while the effectiveness of computer, vision and scanning systems are improving. Automation helps you reduce repetitive actions — the kind that adds no value. The common perception is that automated facilities are dark, free of people and full of robots, but the reality is that automation comes in many forms, ranging from picking systems like pick-to-light to automated conveyors to goods-to-person systems and much more.

For all these benefits, you want to understand the potential problems with any automation project in advance so you can avoid them as you move forward.

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Posted in Automation, Labor & Efficiency|

Making Your Cantilever Rack Safe

October 8, 2020

cantilever rack system storing lumber and tubing, outdoor application

Cantilever racks are built to handle long, heavy loads such as pipe or steel tube, lumber, wood or metal sheets, furniture, elongated crates and lots more. The design is simple–a central column with cantilevered arms extending from one or both sides. Safety is critical in any warehousing or industrial storage area, including cantilever storage. Given the heavy and bulky nature of the loads, here are some things you should be aware of to make sure your racks are safe.

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Posted in Pallet & Warehouse Racks|

Vertical Pallet Movement Options

September 15, 2020

pallet choices for vertical movement
In modern warehouses and manufacturing facilities, the vertical cube should be fully exploited, meaning that you should use overhead air space in your storage and processing operations because it’s less expensive and more efficient. Before you expand or relocate, it’s always better to use that space. You’ve already paid for it and the environmental costs of using it.

Using that space comes with some limitations. One is that you’ll need to transport pallets up to mezzanines or other machinery. While that’s more difficult than moving cartons or other lighter loads, there are ways. Let’s examine some of those options.

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Posted in Mezzanines & Industrial Platforms|

Pallet Shuttles vs. Dynamic Racks

August 6, 2020

pallet shuttle moving in a deep rack bay
For high-volume pallet storage and retrieval operations, dynamic rack systems like pushback, drive-in or pallet flow allow maximum storage in a given area, but each have their limitations. In some instances, a pallet shuttle system may suit the needs of many operations. The costs and limitations are different for each storage method, as shown below.

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Posted in Automation, Labor & Efficiency|

Scissor Lift Table Loading Methods

July 30, 2020

scissor lift tables on an assembly line

Scissor lift tables are a staple of many warehouses and factories because they are versatile and ergonomic. Anytime you need to raise and lower loads for processing, palletizing, depalletizing, picking or maintenance, lifts are a good option.

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Posted in Lifting & Lift Systems|

Conveyor Belt Specification

July 7, 2020

cherries conveyed in a moist area application for further processing

Belt conveyors are used in applications where loads need more support than rollers can give them, usually for things like cartons with irregular bottoms, bags, components and similar loads. They’re sometimes used for small parts, produce or components. The type of belt you specify will usually tie directly to the application, load and operational environment. Here are some questions to ask when you are specifying a conveyor belt.

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Posted in Conveyor Optimization|

Workstation Ergonomics: Eliminating Extreme Movements

June 18, 2020

An illustration of ergonomic reach zone areas on a work surface
With the massive worker compensation costs related to musculoskeletal disorders, finding ways to reduce the risks is imperative. In May, we discussed the impact of work positioning. This time, the focus on the effects of extreme movements and how to counteract the risks.

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Posted in Storage, Organization & Workstations|

How to Position Crossovers on Rooftops

June 9, 2020

A rooftop crossover
A few years ago, I looked out a Chicago hotel room window at the sub-roof of a skyscraper hotel. A long run of pipes and air ducts cut the roof in half, so that anyone who needed to work on it would have to walk a long way around or climb over. Since there were obvious points of maintenance and other equipment on both sides of the obstructions, I’m guessing that maintenance workers were doing exactly that. They needed a crossover, and a roof top isn’t the easiest place to install one, particularly post-construction.

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Posted in Safety & Ergonomics|

How to Add Carton Flow to Pallet Racks

May 21, 2020

Carton flow tracks set into pallet rack in a distribution center
Above: flow storage installed on pallet rack beams in a distribution center

To increase warehouse productivity, reducing the time it takes for people to execute a task is always going to pay off. One way to do that is to concentrate on picking areas so that people are able to get what they need faster and more efficiently. A common gravity flow application is to mount shelves of flow storage on pallet rack so you can mix & match gravity flow and bulk pallet storage in the same structure for both existing and new rack systems.

Whether you’re adding flow storage to an existing rack system or building it from new, this guide should help you get started.

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Posted in Pallet & Warehouse Racks|

The Effect of Work Position on Picking, Assembly, Packing and Shipping

May 14, 2020

Lifting boxes in a warehouse

Work-related musculoskeletal disorders (WMSDs) are a common reported source of missed or restricted work in America. According to the Bureau of Labor Statistics, WMSDs account for over 33% of all worker compensation costs.

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Posted in Storage, Organization & Workstations|

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