Slugs aren't slouches
Slug loading or unloading can be a time saver in reducing the hours spent for truck turnarounds at your docks.
By David Luton -- Modern Materials Handling, 1/1/1999
As a company grows, even the best planned manufacturing site runs out of capacity. Then, the manager of a warehouse associated with the plant faces the challenge of moving into an offsite facility.In many operations it's cheaper to move a warehousing rather than a manufacturing operation. Yet, while the offsite warehouse solves the problem of space, the related issue of maintaining throughput volume may not be so easily resolved, particularly for a loading dock restricted manufacturing site.
In cases like this, there's a need to speed up loading dock turnaround times, particularly if there is restricted staging space at the manufacturing site.
One method to do so is to try slug loading. "Slug loading" (or unloading) is a generic term referring to a variety of materials handling systems that can load or unload the entire contents of a tractor trailer in a fraction of the typical time it takes to load/unload a trailer by a conventional forklift. Thus, one loading dock can handle the output of four to six conventional docks equipped with forklift handling.
These systems are designed to load/unload and stage product; however, subsequent (for unloading) or preceding (for shipping) operations must often be handled by other equipment that properly indexes the pallet loads for takeaway into or retrieval from storage or production. At this point the loads can be interfaced with equipment like AGVs for takeaway.
Many of these systems are customized and application specific. Thus space here does not permit a proper description of the individual attributes of these systems.
There are two types of slug systems:
(A.) Systems requiring trailer modification: Here custom modifications are made to the floor of a truck trailer. For example, conveyor rollers or rails may be added, so that dedicated transport equipment is needed. This type of slug unit may require an integrated loading and unloading system because the trailer modifications may make conventional forklift handling difficult.
Once installed, the slug loading systems permit design of an integrated automated system of supply from a key supplier's manufacturing plant directly onto your assembly line. This type of system can be ideal for a point-of-use dock used for just-in-time replenishment.
(B.) Systems capable of being used with conventional tractor trailers: In this case more flexibility is available because the system can be used at only one end of the transfer. Forklift equipment can do the job at the other end.
This approach permits use at longer transport travel distances. This type of system is also more adaptable to one supplier with multiple vendors or the reverse on receiving.
David Luton is a member of the Association of Professional Materials Handling Consultants (APMHC) and can be reached at 416-225-4703.
Does your handling situation qualify?
To determine if your facility qualifies for one of these slug systems, here's a quick checklist:
- Minimum of 8-10 full tractor trailer loads a day. (Avoid use with LTL only trucks because of the wide variety of truck bed heights involved.)
- Stable unit loads with no overhang and good quality load bases (either pallets, slipsheets, or the like.)
- Sufficient backing and turning room for trucks at the dockface (because building an interface with the trailer is important) along with short transport travel distances.
- Very heavy product weight may become a problem; with a 60,000 lb truck load, the trailer deck height will vary by 3 in.
- Avoid inclined loading ramps if possible; a level dock face is preferable.
- In northern climates, snow and ice buildups may affect how well these systems work.
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