One-millionth Linde truck rolls out of Aschaffenburg

Linde Material Handling has been manufacturing counterbalance trucks at its Aschaffenburg, Germany production site since back in 1959. In March 2021, the one-millionth vehicle rolled off the assembly line and has since been ceremoniously handed over to customer company Colorobbia España S.A., one of the largest facilities in the world for the production of frits, pigments and other products for the ceramics and glass industry.

Even though big celebrations had to be cancelled due to the pandemic, it was a real goosebump moment when the one-millionth counterbalance truck came off the production line at the Aschaffenburg plant in mid-March. Captured on video for everyone to see, the completion of the milestone vehicle was celebrated with a minute-long indoor fireworks display of red Bengal lights, sparklers, smoke and lots of glitter raining down around the figure “1,000,000”.

The next day, the latest-generation Linde diesel forklift truck with a load capacity of 3.5t set off on the journey to its future workplace at Colorobbia España S.A. on the east coast of Spain, with the signatures of all assembly employees written on the back of it. There, it will reinforce a fleet of 60 vehicles.

“We have been relying on Linde brand forklifts for 24 years now and particularly appreciate the trucks’ user-friendliness and safety,” says Gonzalo Trilles de Castro, Managing Director of Colorobbia España S.A. Equally important to him, he says, is a reliable partnership with a company that shares his own philosophy on sustainability, innovation and technology.

“All of this is a guarantee of long-term success, which we share with our customers as a competitive advantage.” The truck’s arrival at the Spanish customer company, which is celebrating its centenary this year, was duly recognised with a specially decorated cake which features sparklers too.

The one-millionth counterbalance truck from Linde Material Handling’s Aschaffenburg headquarters represents the latest highlight in its corporate success story, which now spans more than 60 years. With the “Hubtrac”, Linde’s first forklift truck, the intralogistics specialist offered an industry-defining, technological alternative to the commercial vehicles that had up to then been difficult to operate, usually having a jerky clutch and gear shift.

Thanks to the innovative hydrostatic drive, which allowed a double-pedal control to be fitted, this forerunner was ideally suited for retrieving and storing goods or loading and unloading trucks: no shifting was required when frequently driving back and forth, allowing both feet to be able to rest in a relaxed position on the respective pedal.

Even back then, this resulted in higher efficiency in goods handling and has remained the hallmark of all of Linde’s counterbalance trucks to this day – regardless of whether they are powered by internal combustion engines or electric motors.

Today, Linde Material Handling is once again setting technological standards and making its industrial trucks fit for the future: by means of a wide variety of energy types, intelligent assistance systems and networking as standard.

“Our goal is to enable customer companies to make their material flow processes as efficient and safe as possible, so that they will become even more successful in their core business,” says Stefan Prokosch, Senior Vice President Brand Management at Linde Material Handling. “With products that convince our customers, we already have our sights firmly set on the next milestone in our company’s history – the launch of Linde’s new electric forklift generation in June of this year.”

Increase Efficiency of Storage and Production Processes

FAUN Umwelttechnik GmbH & Co. KG is one of the leading manufacturers of waste collection vehicles and sweepers in Europe. The medium-sized company operates eleven plants in which around 2,000 employees produce a wide variety of special vehicles. At the company headquarters in Osterholz-Scharmbeck, production takes place on a total of 15 assembly lines, which are supplied with components from an indoor warehouse and an outdoor warehouse. In order to optimise the logistical processes between production and warehouse, FAUN decided to introduce a professional warehouse management system with EPG | LFS. LFS has been in use since October 2020 and already ensured an increase in picking performance at the Kardex towers after a very short time.

From huge steel sheets to tanks and pumps to the smallest screws – FAUN Umwelttechnik requires a wide range of individual parts for the production of waste collection containers. They are kept at the Osterholz-Scharmbeck site on a total of 6,500 square metres of storage space so that the assembly lines can access them at the right moment. In 2019, the company decided to introduce a professional warehouse management system to better organise the items. The new solution should above all bring more transparency with regard to the inventory and warehouse processes – as a basis for subsequently being able to optimise them.

Online research and online training

The company researched suitable warehouse management systems with the help of an online tool from the Fraunhofer Institute. During the subsequent discussions with system providers, it quickly became apparent that EPG, with more than 30 years of experience, best met the client’s desire for a professionally positioned provider. FAUN particularly appreciates the modular design of the LFS warehouse management system, which promises plenty of scope for future expansions. Another decisive factor was the innovative training offered by EPG | ACADEMY, which teaches users how to use the system correctly. “We were very pleased with the fast and professional organisation of the online training in the wake of the COVID 19 pandemic,” says Ronny Lößner, who was responsible for the implementation at FAUN Umwelttechnik. “So despite the circumstances there was no delay in our project and we were able to start with LFS as planned.”

Simon Reininghaus, project manager at EPG, praises the constructive cooperation during the implementation: “The project team has excellent process knowledge and was thus able to integrate the processes into the LFS quickly during customising. “ As a result, FAUN was able to record positive effects on employee performance just two weeks after the system was introduced: The picking performance was already higher than before the introduction.

More efficiency through new picking strategy

A large part of the increased efficiency was due to the conversion of order picking to multi-order picking. This allows FAUN employees to process several individual orders in parallel. This saves distances and significantly increases the picking performance. “Picking at the four towers used to be our bottleneck,” explains Katharina Beck, Head of Logistics at FAUN. “The employees could only process orders one after the other and had to go from tower to tower. With LFS, it is now possible to combine several individual orders that are intelligently controlled. In this way, the employees manage more orders in the same amount of time.” In order to make the best possible use of this potential, FAUN has installed two new Kardex towers in which the trays can be controlled automatically by telegram exchange and manual input at the panel is no longer necessary.

Further projects already planned

Beck assumes that performance will continue to increase as FAUN exploits all the possibilities of the warehouse management system. For example, new dashboards will soon be added to make it easier to evaluate key figures. This enables staff to identify weak points in processes and optimisation potential more quickly. In the area of inventory management, transparency has increased significantly: The storage location of individual components can now be determined precisely. In addition, short-term orders from the assembly lines are immediately visible in the system due to the real-time bookings. For the future, FAUN would like to see this transparency in other areas as well. An additional module has already been acquired to map not only the warehouse processes but also the flow of goods between the machine groups. The transport control system is to be implemented as early as next year.

Gemba Process Innovation Can Drive Wave in Europe

With businesses across Europe facing a perfect storm of changing buying behaviours and digital disruption, the time is right for the next wave of business innovation. Hiroyuki Nishiuma, the new managing director at Panasonic System Communications Company Europe (PSCEU), suggests lessons learned from a similarly maturing society such as Japan could help. He predicts the next wave of business innovation will come from ‘Gemba Process Innovation’.

The external pressures shaping business across Europe have never been greater or more varied. As society continues to mature, it brings a host of new challenges and opportunities for industry – forcing them to adapt to thrive. Examples of issues driving this change include those such as changing consumer buying habits, rising environmental and ethical awareness and societal issues such as an ageing population reducing the size of the available labour pool.

In combination, innovation in technology continues to rewrite the possibilities for business. This brings with it both threats and opportunity as disruptors rip-up the traditional rules of commerce, changing the way that manufacturing, supply chains and retail interact. As organisations explore ways to adapt, looking at the experiences of others can be useful. In Japan, Gemba Process Innovation is being used to radically review, redesign and reinvent operations using technology to increase efficiencies and free-up creative potential.

Much-like the business philosophy of Kaizen that came before it, Gemba Process Innovation presents an opportunity to benefit European businesses. But rather than small, incremental continuous improvements that were inspired by Kaizen, Gemba Process Innovation takes a more transformative approach. It combines an in-depth understanding of the organisation and of the latest available technologies to deliver new methods of working.

The gemba is the physical site where value is created. This Japanese word literally translates to “the actual place”. For example, in the supply chain the gemba is where things are made, moved, or sold; the site where value is generated and problems must be confronted: the factory floor, the warehouse, or points-of-sale; these are referred to as the gemba. Each has their own unique processes and goals, but also their own particular challenges. However, the question on the minds of managers of all these operational fronts is the same:

How to innovate and optimise in the face of rapidly changing conditions and customer needs?

In Europe, Gemba Process Innovation is most obviously suited to manufacturing, logistics and retail industries but it has applications across many industries. In manufacturing, Gemba Process Innovation can accelerate automation with the use of technologies such as robotics. In logistics, it can provide the ability to sort, schedule, track and monitor the condition of goods using Deep Learning and sensor technologies connected via the Internet of Things. In the retail sector, it can be used to adopt AI and camera technology to drive personalised digital marketing, as well as automated stock re-ordering to optimise product availability on the shelves.

It all begins with deep business understanding

Of course, technology alone cannot solve these challenges. The first step in successful Gemba Process Innovation is a deep understanding of the existing business process; what works and what doesn’t. This is achieved through consultation, a close observation of the business and industry understanding. However, the workforce itself also has a vital role to play. Employee knowledge about a business’ critical processes is probably one of its greatest assets. Gemba Process Innovation taps into this knowledge.

Often people worry that new technology-driven solutions will automatically mean the loss of jobs, but in my experience, this is not necessarily the case. It is more likely to result in a change of labour requirement. In reality, many of the repetitive and physically intensive job roles are removed and new opportunities are created for the workforce to be engaged in alternative and often more rewarding roles.

Next follows solution design, testing and optimisation

After observation and understanding follows the design of a new solution using technology and processes to deliver new levels of efficiency and productivity. Testing and optimising the solution then becomes the focus to ensure as much value as possible can be delivered from the innovation. Gemba Process Innovation requires a combination of hardware, software engineering and system integration to provide the total solution. In Japan, Panasonic has more than 100 years of business experience to draw upon and has been an innovator in Gemba Process Innovation. It first used the approach to continually evolve its own business and then expanded by offering the service to its customers.

The time is now right to introduce Gemba Process Innovation in Europe. As the European market need grows, Panasonic will continue to strengthen and expand its solutions capabilities here. The process has already begun with the acquisition of European-based company Zetes, a specialist advisor in solutions using innovative technology in the supply chain. Globally, more recently, Panasonic has also invested in a 20% stake in Blue Yonder, a leading end-to-end supply chain software provider; further strengthening its knowledge base and capabilities for the future.

The first business results of Gemba Process Innovation are also already being seen in European businesses. Examples include the deployment of Panasonic’s Visual Sort Assist System (VSA). VSA combines scanning technology, goods detection technology and projection to speed up the process of sorting items on a conveyer belt, through the semi-automation of item checking and routing. The system is designed to be used in sites where the workers pick, relocate, or remove items such as in production & retail warehouses, and sorting and distribution centres.

In logistics

With online sales growing rapidly across Europe and a 69% increase in European parcel deliveries forecast by 2021, Gemba Process Innovation is already benefitting the logistics industry in delivering a quality service under increasing pressure. When one of Europe’s leading parcel delivery companies wanted to offer customers improved real-time tracking of their deliveries, from sorting centers to delivery address they turned to Panasonic. After studying the requirements, Panasonic recommended a combined software and hardware solution for the business. Field trials were conducted using new Panasonic rugged handhelds and Zetes Chronos delivery software to test performance. The electronic proof-of-delivery software helps control and improve collection, delivery and related management processes. It connects drivers, back-office workers and logistics management to provide real-time visibility on goods, vehicles and returnable assets. This ensures perfect delivery, every time, and offers customers visibility on the status of their shipments.

In conclusion, as European businesses position themselves globally to take advantage of the next wave of technological innovation, Panasonic plans to assist them in achieving their goals by becoming a full service provider focusing on these types of industry solutions that transform the gemba – the place where value is created.

BEUMER Group wins Chairman’s Manufacturing Performance Award 2020

With its AFR Systems (Alternative Fuels and Raw Materials) business unit, BEUMER Group supports cement producers in feeding calciners and main burners with alternative fuels and raw materials. The system provider develops complete solutions for efficient handling of different materials. The Portland Cement Association (PCA) has now named BEUMER Group as a winner of the renowned Chairman’s Manufacturing Performance Award 2020.

 The production of cement has always been one of the most energy-intensive operations. In order to avoid expensive primary fuels such as carbon, gas and oil, and to produce cement in a more economic and sustainable way, many factories have relied on alternative fuels for the incineration process in the calciner for several years. These include waste tyres, rubber chips, plastic or other oleaginous mineral materials as well as processed industry/household waste. With its AFR Systems business unit, BEUMER Group supports cement manufacturers with extensive know-how and customised systems. With this capability, it is able to supply and install the whole chain from acceptance and unloading of the delivery vehicle up to the storing, conveying and feeding process of the solid alternative fuels for the specific user. The customer receives everything from one source, thus having a unique contact. The system provider has now been honoured for this with the Chairman’s Manufacturing Performance Award 2020, presented by the Portland Cement Association (PCA), a leading organisation in the cement industry. “I am very honoured to receive this recognition on behalf of BEUMER Group,” said Brian Giese, BEUMER Corporation Director of Business Development, Conveying & Loading. “It demonstrates our commitment to support cement manufacturers in their efforts to make production greener and more sustainable.”

 

Founded in 1916, the PCA is the premier policy, research, education, and market intelligence organization serving America’s cement manufacturers. The award recognises achievements in three areas, the development of innovative products, unique processes, and best-in class-practices, and was presented to three companies this year.

BEUMER Group wins Chairman’s Manufacturing Performance Award 2020

With its AFR Systems (Alternative Fuels and Raw Materials) business unit, BEUMER Group supports cement producers in feeding calciners and main burners with alternative fuels and raw materials. The system provider develops complete solutions for efficient handling of different materials. The Portland Cement Association (PCA) has now named BEUMER Group as a winner of the renowned Chairman’s Manufacturing Performance Award 2020.

 The production of cement has always been one of the most energy-intensive operations. In order to avoid expensive primary fuels such as carbon, gas and oil, and to produce cement in a more economic and sustainable way, many factories have relied on alternative fuels for the incineration process in the calciner for several years. These include waste tyres, rubber chips, plastic or other oleaginous mineral materials as well as processed industry/household waste. With its AFR Systems business unit, BEUMER Group supports cement manufacturers with extensive know-how and customised systems. With this capability, it is able to supply and install the whole chain from acceptance and unloading of the delivery vehicle up to the storing, conveying and feeding process of the solid alternative fuels for the specific user. The customer receives everything from one source, thus having a unique contact. The system provider has now been honoured for this with the Chairman’s Manufacturing Performance Award 2020, presented by the Portland Cement Association (PCA), a leading organisation in the cement industry. “I am very honoured to receive this recognition on behalf of BEUMER Group,” said Brian Giese, BEUMER Corporation Director of Business Development, Conveying & Loading. “It demonstrates our commitment to support cement manufacturers in their efforts to make production greener and more sustainable.”

 

Founded in 1916, the PCA is the premier policy, research, education, and market intelligence organization serving America’s cement manufacturers. The award recognises achievements in three areas, the development of innovative products, unique processes, and best-in class-practices, and was presented to three companies this year.

Sustainable Innovation

Bonfiglioli is encouraged by its future opportunities, boosted by a new Bologna production plant and a new frequency inverter series. Paul Hamblin reports.

“Innovation becomes sustainability,” said Fausto Carboni, CEO of Italian gear motor and drive manufacturer Bonfiglioli at a September press conference. He painted a bullish picture of the
company’s recent performance, with revenues up 6.7% at €973 million last year, incorporating EMEA figures up 5% and North America up 20%.

Looking at the much more volatile recent months, he is encouraged by the contrast between April and August numbers this year. He quoted the example of India, down 99% year-on-year in April, for obvious reasons, but up 10% year-on-year in August. In an intriguing signal for the wider economy, he revealed that China will be Bonfiglioli’s most important market in 2020, with numbers boosted by 64% year-on-year in the territory. While Italy, France and Spain are all understandably down by over a half this year, Germany is a predictable outlier, with a less damaging slowdown than its European neighbours. Mr Carboni suggested that Germany’s growth is also boosted by its strong progress with the Circular Economy.

He went on to outline how Bonfiglioli has adapted to virus restrictions with new shift patterns, improved distancing, common space procedures and regular temperature checks of staff. These
have been incorporated at its new plant for industrial gear motors at Bologna. “#WeNeverStop is our new mantra,” he revealed. This promise is illustrated by the launch of a new premium frequency inverter series.

Bonfiglioli says that the new AxiaVert Series provides the ultimate combination of flexibility, modularity and connectivity, aimed at offering an optimal response to specific industrial application requirements across a wide range of sectors and with different degrees of complexity. AxiaVert is now available in 4 sizes, with a power range between 0.25–15 kW. Higher power versions will be released at a later stage.

The advanced digital and open communication protocols, complying with automation and Industry 4.0 standards, allow a smooth integration into automation networks, thanks to the compatibility
with a great variety of fieldbus protocols and machine controllers. Communication encryption is embedded by design in AxiaVert to ensure secure communication. In addition, thanks to
condition monitoring functions on the key inverter components as well as on the gearmotor critical parameters, AxiaVert is able to provide real time diagnostics, energy optimization and
predictive maintenance information related to the motion system up to the entire machine.

The wide range of advanced integrated functional safety functions, in compliance with EN ISO 13849-1 and IEC 61508 international standards, are available in different versions, to select the most suitable option in terms of costs and performance and match the actual needs. This approach simplifies configuration and reduces the need for external safety components, while ensuring a safe and controlled operation of different movements (e.g. lifting applications), thanks to Safe Brake Control and fast spindle axes with Safe Limited Speed, even sensorless.

Thanks to its modular structure and PLC software programmability, the system can be flexibly adapted and customized to meet many different application requirements, by defining the proper
software parameters and functions, and selecting the most suitable hardware modules, such as communication or encoder modules, variants and accessories. In addition, the AxiaVert Series offers a great variety of frame and power sizes, mounting variants and cooling concepts for greater freedom of design.

Great process versatility is ensured by the high compatibility with a wide range of motors (asynchronous, synchronous, synchronous reluctance) and by its high speed, position and torque control
accuracy, both for open and closed loop applications. Finally, user-friendliness is ensured by AxiaManager engineering software for programming, commissioning, operation and monitoring of AxiaVert. AxiaManager is available as a Windows PC GUI and as a mobile App for an instant access to the drive status and configuration with a simplified user interface.

Support Connected Manufacturing

  • Microlise has joined manufacturers’ organisation MAKE UK, becoming a member alongside the UK’s leading manufacturers and innovators. With significant expertise in the area of connected technology and the Industrial Internet of Things (IIoT), Microlise looks forward to collaborating with and supporting members, particularly as the supply chain landscape and trading environment beyond Brexit presents a unique set of challenges that digitisation can do much to overcome.
  • Britain is one of the world’s biggest manufacturing nations, with almost 3 million people working in the sector and delivering almost half of all exports. UK manufacturers drive over 60% of all research and development, driving change and transformation. According to David Midgley, OEM & Channel Director at Microlise, the company’s early involvement has already proved to be constructive:
    “We have taken part in a number of events and webinars and can see lots of potential synergy between ourselves and other like-minded manufacturers. As a proud UK-based designer, developer and manufacturer of the hardware, firmware and applications that underpin our connected platform, and our on-highway telematics and technology solutions, we look forward to participating more widely and to sharing our thirty-plus years of global experience with other members.”
  • Charlotte Horobin, Region Director, Make UK added: “I am delighted to welcome Microlise into the largest community of UK manufacturers. Microlise is an ambitious and dynamic company that brings real technological expertise to the table. I look forward to working with them through Make UK’s portfolio of services, events and network to support their business growth and drive forward technological innovation within the sector.”
  • Nottingham based Microlise is the proud holder of two consecutive Queen’s Awards for Enterprise – International Trade in 2018 and Innovation in 2019, in recognition of the industry-leading solutions we export around the world, most notably to Tata Motors in India. The company works with a number of manufacturers, such as JCB in the off-highway space, and MAN Truck & Bus on-highway, in the UK and across the Middle East & Africa, supporting these world-leading organisations to gain insight into their own products and enhance customer experience, through our connected offering.

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