Making best use of space in a warehouse can be a challenge. And it's no easier to cut costs and save handling time, either. But automotive supplier Dana Corp. has achieved all three with a new fleet of narrow-aisle lift trucks.

At its Gordonsville, Tenn., facility, Dana manufactures automotive products from axles and drive shafts to brake components. To handle such a diverse range of products, collapsible wire containers, 48 by 40 inch wood pallets, and plastic totes and pallets are used. In addition, loads are constantly moving not just within the facility but also to an outside storage area. As a result, Dana needs lift trucks capable of both indoor and outdoor use to maximize materials flow between storage and production.

That capability trims costs because it reduces the number of lift trucks needed to move loads. It also saves time by eliminating double handling. Allowing only one truck to move a load directly between outdoor storage and indoor areas (and back again) improves materials flow.

Then there was the matter of freeing up space in the facility for new production equipment. That meant indoor storage and staging areas needed to become more tightly packed. The company had already reduced storage aisle widths to 8 feet from 15 feet. With the new four-truck fleet, aisles as narrow as 6 feet 6 inches are possible.

"We were able to increase our production space at Gordonsville by at least 20%," says Mark Stebing, Dana Corp. training, ideas and safety coordinator. "Reworking the interior layout for narrow-aisle storage and relying on a flexible, multi-purpose truck was less expensive than the anticipated cost of new construction."

During the lift truck evaluation process, Stebing considered both electric and internal combustion trucks.

"We evaluated electric vehicles but full-shift operation wasn't adequate," he says. "Battery change time reduced the operating cycles available to one shift or another. The significance of downtime can't be over emphasized."

The final benefit of the new fleet is an operator-friendly training program that covers safety and operational procedures. In addition, the truck's improved visibility and no rear end swing make it easier and safer to drive. The features also save products and racks from being damaged in the process.

With Dana's materials handling goals accomplished and time and money saved, the company will continue to enjoy the benefits of its indoor/outdoor fleet.