ProMat 2009: Solution central
With a record number of exhibitors, ProMat 2009 (held January 12-15 at Chicago's McCormick Place) provided a wealth of ideas for improving productivity at your company. The products and technologies on the following pages illustrate key products and news that Modern's team of editors discovered at the show.
Staff -- Modern Materials Handling, 2/1/2009
For Modern's complete coverage of ProMat 2009, visit www.mmh.com/promat
SSI Schaefer unveiled fully automated case picking system
The Schaefer Case Picking System (SCP) was introduced in a press conference. The SCP system seamlessly automates all processes from receiving, de-palletizing, selecting, sequencing and palletizing of mixed case palletloads, said Cory Flemings, executive sales manager for the automation and systems division of SSI Schaefer.
"The system has the capability to handle anywhere from 30,000 to 300,000 cases per day with higher performance and fewer errors than traditional distribution centers," Flemings said. By removing labor from the process, users are expected to attain a drop in cost-per-unit shipped by up to 30%.
Initially created for use in high-SKU environments like grocery and consumer electronics handling, the system generates savings through advanced computer simulation of pallet-load building. The software that controls the order-picking and sequencing system starts with order information and builds cube-optimized pallets in virtual space first.
Then the software tells the systems which trays to deliver to the pick station—and in what order. This results in palletizing robots receiving products in the correct sequence, allowing the SCP to build cube-optimized, store-ready pallets by family group.
Product characteristics are entered into the system through the Schaefer Vision System cube dimensioning unit that collects and stores physical data. This information is used by the software to calculate volume-optimized and scalability-oriented pallets.
Further, a hybrid packing station with dual encased pallet lifts ensures that the robotics always have a pallet in process. While the system finishes building a pallet on one lift, the other lift lowers its pallet through a two-level wrapping system that ensures pallet stability and integrity.
The first system is currently being built in York, Pa., and is expected to be operational in January 2010, and a second system is under construction in Germany, Flemings added.
HK introduced a micro-load AS/RS
HK Systems, Inc. introduced a new automated storage and retrieval system (AS/RS) designed to handle micro-loads—cases and totes weighing up to 75 pounds—in applications requiring dense storage and high throughput for a diverse set of SKUs, cases and/or totes. With vertical speeds of up to 600 feet per minute (fpm) and horizontal speeds of up to 1,500 fpm, and the ability to add up to four extractors, the system can execute up to 500 putaways and retractions per hour.
"U.S. commerce has been redesigning the unit load from pallets to cases, and now from cases to eaches," said Mike Kotecki, senior vice president. "This family of machines is designed to work in applications such as case and tote replenishment in a pick-to-light environment, or carton flow replenishment in a case-picking application."
Manufactured in HK's plant in Salt Lake City, Utah, the machine can handle cases and totes with dimensions ranging from 8 inches to 24 inches. With the ability to support an array of extractor mechanisms, it creates a more efficient and more responsive supply chain, capable of fulfilling smaller order sizes at increased frequency.
Key features of the micro AS/RS machine include industry leading speeds and accelerations, scalable design, multiple and flexible extractor options, and dual and independent lift carriages. The system relies on dynamic shelving—warehouse management (WMS) software technology—to maximize the use of shelf space.
HK Systems, Inc. introduced a new automated storage and retrieval system (AS/RS) designed to handle micro-loads—cases and totes weighing up to 75 pounds—in applications requiring dense storage and high throughput for a diverse set of SKUs, cases and/or totes. With vertical speeds of up to 600 feet per minute (fpm) and horizontal speeds of up to 1,500 fpm, and the ability to add up to four extractors, the system can execute up to 500 putaways and retractions per hour.
"U.S. commerce has been redesigning the unit load from pallets to cases, and now from cases to eaches," said Mike Kotecki, senior vice president. "This family of machines is designed to work in applications such as case and tote replenishment in a pick-to-light environment, or carton flow replenishment in a case-picking application."
Manufactured in HK's plant in Salt Lake City, Utah, the machine can handle cases and totes with dimensions ranging from 8 inches to 24 inches. With the ability to support an array of extractor mechanisms, it creates a more efficient and more responsive supply chain, capable of fulfilling smaller order sizes at increased frequency.
Key features of the micro AS/RS machine include industry leading speeds and accelerations, scalable design, multiple and flexible extractor options, and dual and independent lift carriages. The system relies on dynamic shelving—warehouse management (WMS) software technology—to maximize the use of shelf space.
AC-powered reach truck at Toyota
Toyota Material Handling, U.S.A., Inc. unveiled a line of AC-powered reach trucks designed for DCs, retail operations, refrigerated warehouses and third party logistics (3PL) applications. The new line is available in three models, including a single reach lift truck in 3,500- and 4,500-pound lifting capacities and a 3,000-pound capacity double reach truck.
While AC-powered trucks are not new to the market, the new line is distinguished by an AC-powered drive system, an AC-powered hydraulic system (on 36-Volt models) and maintenance-free electric disk brakes. Because the AC system contains no motor commentator, brushers or springs, maintenance costs are lower. The drive system enables operators to handle more pallets per hour and per shift for increased productivity.
"The new series was designed with the specific needs of our warehousing customers in mind, including product travel speeds that are up to 17% quicker than previous models, and fewer service intervals," said Brett Wood, president.
While the new series is scheduled to go into production this month, Toyota also debuted a hybrid concept lift truck that uses the same hybrid technology used in the Toyota Prius. The truck combines the best of electrical and internal combustion engine technology, allowing the vehicle to shift between battery and engine mode to operate with optimum fuel and emissions efficiency. Toyota is also exploring concepts that may use compressed natural gas, fuel cells, biodiesel and ethanol.
While there is no date set for production, "the concept vehicle demonstrates our global charter to develop innovative technologies and products that are environmentally responsible and economically viable," said Wood.
Industry insights from materials handling icon Don Frazier
Don Frazier, current chairman of Frazier Industrial Company—and namesake of the new Don Frazier Material Handling Technical Training Center—has been a materials handling industry pioneer and leader for more than six decades. As a founding member of the Board of Directors of the Material Handling Education Foundation, Inc. (MHEFI), his campaign for and support of technical training for students in high schools and technical colleges is recognized by the Foundation's Board by the dedication of this program in his name.
Frazier's first job out of the Army Air Corps was as an office boy with the publisher of Modern Materials Handling. He cites his 3.5 years there as providing him with the foundation of his education in unit load handling.
Equipped with his knowledge and a $2,000 inheritance, he started Frazier Industrial Company in New Jersey in July 1949. Asked by his first customer to build racking for two-level pallet picking, his first structure consisted of 2 x 4 lumber that ended up as splinters. Frazier rebuilt the racks from structural steel pipe and fittings, setting the stage for the company to become a leading supplier of industrial racks and related equipment.
Frazier attributes most of his success as a small company manager to the industry associations and memberships he maintained. He participated in and provided leadership to the American Material Handling Society (AMHS)—now known as Materials Handling Management Society (MHMS)—the Rack Manufacturer's Institute (RMI) and the Material Handling Industry of America (MHIA).
Frazier has never missed a ProMat, including this year's, since the show's inception in 1947. In fact, Frazier's proposed "golden horseshow" show floor layout—enabling a more equitable distribution of floorspace between large and small exhibitors—has been in effect since the 1960s.
Upon his retirement from the day-to-day dealings at his company in 1979, Frazier relocated to Arizona. His unquenchable thirst for knowledge has led him to pursue his interests in archeology and literature.
Frazier shared some of his insights about the materials handling industry: past, present and future.
MODERN: In all the ProMat shows you've attended—including the first show in Cleveland in 1947—how has the show changed?
FRAZIER: To say how it's changed, it needs a little description of what it was like in 1947. Before World War II, there were almost no companies in the United States with a lift truck, and fewer than that with fork trucks and pallets. The war made movement of large volumes of materials mostly through Liberty ships to Europe and the Pacific Rim.
The Armed Forces had to have supplies with speed and in quantity, and manpower alone couldn't solve it. Hence, the development of fork trucks and pallets to unitize movements more expeditiously. By the end of the war, the larger companies supplying the military had fork trucks and some forms of pallets. And the rest of the industry—seeing the benefits of unit loads—scrambled to catch up.
The January 1947 material handling show was the first chance for most companies to see and discuss unit load handling. Before the war, there were hoists, cranes, conveyors and two-wheel and four-wheel hand trucks as the principal tools for moving goods. But there were almost no standards. At the 1947 show, some of the other peripheral handling tools were represented, but the fork truck was totally dominant for at least the next 30 years.
MODERN: What's the most interesting advance you've seen in materials handling throughout your career?
FRAZIER: Computerization and the automatic storage and retrieval systems (AS/RS) were the most interesting, but the whole push-button data technology of industry has revolutionized the handling of everything.
MODERN: What are your thoughts on the importance of education to building the materials handling workforce of today and for the future?
FRAZIER: Teach the new material handling generation that job education is on-going, beyond general, high school and college diplomas. If the material handling worker applies him/herself, there is no top limit to achievability.
MODERN: What advice would you give to the new workforce entering the material handling field?
FRAZIER: Pay your bills, keep your word and respect the people you work with—bosses and underlings both.
MODERN: How did your time at Modern Materials Handling influence your own career in the field?
FRAZIER: I spent 3.5 years at MMH in the 1940s. It was much more important to my growth and learning than any college degree could have served me. I got in at the bottom of a revolutionary technology and grew with it to a career experience far beyond my wildest expectations.
MODERN: In your opinion, what is the importance of MHIA to the materials handling industry?
FRAZIER: Trade associations are vitally important to get membership to focus on togetherness toward the collective betterment of the industry through standards, safety practices, statistics and education.
MODERN: Looking into your crystal ball, what are your predictions for the future of materials handling?
FRAZIER: In the more than six decades that I have observed material handling, each decade has had more growth than the one before. There have been a few bumps in the road, but our industry is far more responsible than ever before, and my crystal ball says that in the decades ahead of us, our industry and the world we live in will continue to improve and become even more responsible. —Sara Pearson Specter, Editor at Large
Hyster debuted line of electric lift trucks
Hyster representatives with one of the new electric lift trucks. From left: Brett Schemerhorn, vice president of national accounts; Mike Adams, regional sales manager of electric products; Lorri Lewis, manager of promotions and events; and Rick Warren, vice president of sales, western region and Canada.
A new line of electric lift trucks was introduced by Hyster Company. Offering improved ergonomics and enhancements for easier operator use, the AC-powered E45-70XN was showcased in several special in-booth demonstrations.
"The Hyster E45-70XN series was designed with the comfort and productivity of the operator in mind," said Hyster president Paul Laroia. "This is achieved without compromising efficiency. By incorporating the latest technological advances and ergonomic features, our new electric product is one of the most operator-friendly lift trucks available today."
The remodeled operator compartment offers increased foot and leg room. It has also been improved ergonomically with a relocated dash display for better visibility and pallet control. Additionally, a new hood makes it easier for the driver to enter and exit the truck. Other features include a removable floor plate for quick maintenance and maximum battery service access to reduce downtime, Laroia added.
Additionally, the truck's traction motor—constructed with steel skin and cast end bells for maximum air flow—features speed sensors that accurately monitor speed over the entire motor operating temperature range.
"All of the vehicles in this series have been through comprehensive environmental and electrical testing to ensure the trucks exceed all international standards for industrial lift trucks," Laroia said.
Intelligrated introduced long carton logic
Intelligrated’s long carton logic adjusts to cartons that are longer than established zones on MDR conveyor, said Jim McKnight (left), VP of systems sales and marketing, and Greg Borchers, VP of concepting and estimating.
Materials handling users with long cartons can now take advantage of the lower energy and maintenance costs provided by motorized driven roller (MDR) conveyor, according to Jim McKnight, vice president of system sales and marketing for Intelligrated, thanks to long carton logic technology.
This new feature, which has been integrated with Intelligrated's conveyor control software, enables cartons, totes and products to be accumulated and conveyed properly even if they are longer than the zones established by the MDR conveyor system.
"Prior to this software development, if product was longer than the zone on the MDR conveyor, it would most likely cause a jam at the photo eye because the product was spanning two zones," McKnight said. "That would require someone to physically remove the product, causing a major disruption in operations and resulting in downtime and lost productivity."
Some solutions available on the market worked around this problem by removing or reducing the system's ability to detect jams, which could compromise the machinery, or they would use double zones, which cut the rate of conveyance, compromising the throughput of the system. The solution introduced by Intelligrated solves this problem by providing dynamic zone length adjustments.
"The long carton logic automatically adjusts the size of the zone to accommodate products that are longer than the zones established by the conveyor system," says McKnight. "That way, the system can handle a wider variety of product, which decreases non-conveyables and increases operation efficiency."
Manhattan provides visibility to 3PLs
The latest release of Manhattan Associates' Extended Enterprise Management (EEM) solution features instant visibility for third-party logistics providers that need to manage orders, shipments and inventory. The solution enables 3PLs to consolidate and transport inventory by managing partner-to-partner shipping and providing hubs with the ability to complete direct fulfillment.
"EEM specifically supports our 3PL customers by providing crossdocking and flow-through support that allows 3PLs to play a key role in the pop-up supply chain," said Eddie Capel, executive vice president for product management and customer support. "This capability is seamless due to the visibility EEM provides, along with the capability to make quick decisions should an unexpected event occur."
Manhattan describes the pop-up supply chain as an approach that allows retailers and manufacturers to dynamically adjust transportation and inventory networks to meet changing seasons or trends. Manhattan's EEM is designed to connect trading partners and customers to provide the overarching visibility and event management capabilities required to successfully manage inventory through global supply chains, including those with dynamic and changing demand.
Features include: a centralized, browser-based solution that allows 3PLs to automate communication; end-to-end visibility of orders, shipments and inventory from sourcing to cargo delivery; a single, real-time view for greater inventory control and optimal fulfillment channels; and the ability to track events in real time and respond based on alerts to critical exceptions.
FKI Logistex shows the key to security
Mike Thomas, FKI Logistex product manager, with the Logistex MR200 motorized roller conveyor, a time-saving, energy-efficient system that is part of the company’s new Logistex case conveyor product family.
FKI Logistex, a supplier of integrated materials handling solutions, announced the release of NetLok, a secure information infrastructure for remote connectivity.
NetLok features a closed-loop login procedure with a restricted login provision, allowing secure, one-time access to the network by authorized staff. With reliable 24/7 diagnostics availability, FKI Logistex technical support staff can log-in remotely to troubleshoot, identify and respond immediately to the problem. NetLok proactively detects connectivity problems, reducing potential lapses in diagnostics. The system can also automatically track, record and archive an audit of remote network access.
"NetLok is a logical and necessary answer to the data security challenges today's networked operations face," said Eric Rice, director of technical support for FKI Logistex North America.
FKI Logistex also showcased the Logistex case conveyor product family. The conveyor loop on display demonstrated the Logistex RT200 right-angle transfer, NB200 narrow-belt and MR200 motorized roller conveyor, as well as the robotic palletizing and depalletizing capabilities.
The company also demonstrated solutions for high-speed sortation, including the energy-saving tilt-tray and cross-belt sorters, and the UniSort XV sliding shoe sorter, which provides throughputs of up to 400 cartons per minute.
Steve Ackerman, president, FKI Logistex North America, said, "We're living up to our commitment of investing in our company and our industry. We've spent more money on new products in the last two years than in any other two-year period in our company's history."
Yale introduced new electric truck
Yale Materials Handling Corporation introduced the ERC-VG, the next generation of electric rider trucks. These energy-saving vehicles feature an operator's capsule that goes above and beyond intuitive design and spacious comfort. Designed for a variety of applications, from short shuttles to long runs and ramp usage, the ERC-VG offers adjustable performance parameters that allow for customization to the specific needs of the application or the operator. The extended shift functionality provides a balance between battery run time and truck productivity.
To meet heavy duty performance requirements, the trucks are built with industrial grade critical components. The new trucks are also designed with a focus on "human engineering" to minimize operator strain and fatigue. Controls are positioned for easy, intuitive operation. The floorboard is open and spacious. The steering wheel and operator's seat are offset to reduce fatigue and improve efficiency.
As one of the largest volume producers of zero emissions lift trucks in the North American market, Yale's ERC-VG complements its existing line of lift trucks that improve efficiency and reduce energy consumption at its customers' operations.
Daifuku and Webb showcased innovative, automated solutions
Brian Stewart, COO of Jervis B. Webb highlighted the company’s latest AGV and AS/RS offerings.
For the first time since Jervis B. Webb was acquired by Daifuku Co., Ltd. in 2007, Webb and Daifuku America Corp. jointly exhibited at ProMat 2009.
The companies showcased automated storage and retrieval (AS/RS) and automatic guided vehicle (AGV) solutions. These products highlight the strengths the combined companies bring to the materials handling table, according to Brian Stewart, Webb's senior vice president and chief operating officer.
"Together, Daifuku and Webb offer the widest range of material handling technologies in the industry," said Stewart. "Our demonstration at ProMat shows how products from both companies work together to increase production in the warehouse, distribution center or manufacturing facility."
Solutions featured at the booth included:
-
A new, faster unit load AS/RS. A high-density pallet buffer, the system is designed to maximize vertical storage space while maintaining a compact footprint.
-
SmartLoader Model 3000, Webb's latest automatic trailer loading/unloading AGV, which can move loads up to 3,000 pounds and is available with single, double or single-side shift forks.
-
SmartCart Model 300. This counterbalanced fork automatic guided cart is guided by magnetic tape and can be used in a variety of applications, including transporting loads to and from a stretch wrapping system.
In the solution on display, the AS/RS receives palletized loads from both the automatic guided cart as well as the trailer loading/unloading AGV.
Raymond's iWarehouse keeps watchful eye on lift truck fleet
Raymond representatives (from left) Joe Lafergola, manager of fleet services;
David Furman, vice president of marketing;
and Scott Craver, manager of business and information solutions
tout the features and benefits of Raymond’s new fleet optimizer system.
The concept of doing more with less isn't new, but the tools are. Lift truck maker Raymond Corp. has introducediWarehouse, an innovative fleet optimization system that provides real-time information and enables warehouse and DC managers to improve performance of operators and lift trucks.
Raymond's president and chief operating officer Jim Malvaso said, "We bring technology to the marketplace that enhances operations and delivers a bona fide improvement to our customers."
iWarehouse connects to the lift truck vehicle manager with a single connector and offers a constant data flow through a wireless network. Access to real-time information can result in more production from operators and technicians (whose labor accounts for 80% of lift truck costs); reduce the potential for accidents; diagnose truck issues remotely; benchmark performance to develop best practices; optimize fleet capital and maintenance expenses; and move product more efficiently and profitably.
The iWarehouse system is available with a variety of modules to meet specific application needs. Malvaso explained, "We've entered a new age. We view our trucks as more as than transport vehicles, they're also vehicles that will provide data and information to the user. Inside every truck is computer with a tremendous amount of data. Capturing the information in real-time helps users to be more productive and ultimately more profitable."
"True, we're in a recessionary environment, but material handling is the heart and soul of the supply chain. The need for our products and services is still there; it's fundamental to our culture. We understand our contribution is larger than just providing fork lift trucks," he said.
Dematic's Multishuttle optimizes order assembly
Dematic, a provider of automated logistics solutions, has introduced the Multishuttle, a flexible automated storage and retrieval system (AS/RS) staging solution for applications that require dynamic, high rate, product sequencing to support applications such as: order assembly, goods-to-the-person picking, and pick-face replenishment.
"The Multishuttle solution is ideal for supplying product-to-piece pick order fulfillment modules or mixed pallet building operations," said Ken Ruehrdanz, Dematic's market development manager. "It can also be applied as a short term buffer storage system or as a parts support system for production operations."
The key attributes include high rate capacity, the ability to accommodate load sequencing requirements, and adaptability to existing building layouts. The system consists of multiple levels of AS/RS rack structure, carrier vehicles, conveyor and software. Each level of the rack structure includes a carrier that travels horizontally to access stored loads, typically totes or trays. A shuttle device on each carrier accesses the loads in the rack. Since a carrier is captive in each aisle and on each level, ultra high throughput capacity is achieved. At the end of each aisle, a vertical conveyor brings the load to the input/output conveyor. Load sequencing occurs as loads are retrieved in order for fulfillment.
"The simplicity of the modular carrier vehicles allows high system uptime, system redundancy, and low power consumption," said Ruehrdanz.
New VLM and mini-load AS/RS from Diamond Phoenix
Diamond Phoenix introduced two new products at ProMat. The vertical lift module (VLM) is a single bay SMARTdepot VLM. The new machine is designed to meet additional customer needs where a single bay, rather than a multi-bay, is requested. The new unit can handle loads of up to 1,100 pounds per tray and reach heights of up to 50 feet.
The new MaxTriever MiniLoad storage/retrieval machine (SRM) is a stacker crane that efficiently handles totes, cartons, boxes and other items and will help organizations realize high capacity and high speed throughput. The crane operates comfortably in cold storage, coolers and ambient warehouse temperatures and uses standardized and proven subsystems for high reliability.
Both products are designed to enhance Diamond Phoenix's portfolio of solutions for manufacturing, distribution and other organizations looking to improve efficiency and overhead costs while maintaining flexibility for peak seasons and slow downs.
Kardex AG acquires Kardex Systems
Kardex AG commented on its recent agreement to acquire the assets of U.S. competitor Kardex Systems, Inc., whose offerings include mobile shelving and media station storage products. Remstar International—a provider of automated storage and retrieval solutions—is a company of Kardex AG Remstar International Group.
In explaining the Kardex Inc. acquisition at a ProMat press conference at one of Remstar's booths, Jos De Vuyst, CEO of Kardex AG, pointed out that while it was "good to have our name back," the move was more than just the buy up of a brand name. De Vuyst said Kardex AG also plans to continue the Kardex Inc. production site in Lewistown, Pa., and leverage its distributor network.
Mobile shelving and media cart production will continue at the Lewistown site, and horizontal carousel products assembled at a Remstar site in Westbrook, Maine, will begin being produced at the Lewistown plant. The Westbrook site will continue as a sales, marketing and support site.
Kardex Systems Inc. posted sales of approximately $21 million in its 2007 financial year, and has a staff headcount of 100.
View All On-Demand Webcasts
