Tag: Materials Handling

When POLI-TAPE required various loading equipment in confined spaces working at heights of up to 12 metres, Hyster supplied a rental fleet of forklifts equipped with driver assistance systems and tracker. The result was transparency and efficiency in POLI-TAPE’s warehouse and production facilities with minimal downtime and damage.

Whether shop windows, vehicles, or textiles, films from POLI-TAPE are used to cover and label a wide variety of surfaces. Products of the family-owned company from the western German state of Rhineland-Palatinate are present in more than 90 countries. At the headquarters in Remagen and in subsidiaries in the USA, France, and Italy, around 400 employees are committed to top quality. They produce films for transfer to textiles, self-adhesive digital printing, and special films for labelling and advertising technology.

Such a product portfolio entails a variety of sensitive materials and complex processes. In addition to the normal Euro pallet, the company moves oversized loading equipment, for double transports or two-metre rolls of film weighing several tonnes. For this variety of tasks, POLI-TAPE was looking for a partner who could cover all transport tasks along the entire supply chain from a single source.

From film to glue to paper, a wide variety of materials arrive in Remagen. Finished products leave the company every day. A shift operation supplies and removes production over 16 hours via seven ramps. 40 forklift trucks maintain the flow of goods; if it comes to a standstill, customers all over the world are waiting for their goods. One of the most critical breaking points in this process is the twelve-metre-high warehouse. If a high-bay or reach truck fails in the narrow aisles, in the worst case one of the lines comes to a standstill. The precisely coordinated orders for films in all possible shapes and colours have to be rescheduled.

Another challenge is the lack of space. 27,000 sq m for storage and production are used up to the last corner. There is no room for space-consuming turning manoeuvres and the number of internal movements is constantly increasing. At peak times, the vehicle fleet moves up to 1,000 fully packed loading units on a single day. Indoors, it is particularly important to drive quickly, yet carefully. Outdoors, forklifts have to negotiate uneven floors to prevent the goods from sliding. Hyster uses its broad portfolio to ensure little transport damage and maximum efficiency.

Equipment

The electrified fleet includes high rack and reach trucks, high speed trucks, pallet trucks and front stackers of the following product ranges:

• S-series pallet trucks with payloads of 1.4 to 2.0 tonnes
• P-series pallet trucks with and without platform for payloads from 1.6 to 3.0 tonnes
• Stand-on/cross-seat pallet trucks up to two tonnes capacity of the RP series
• Customised high rack and reach trucks model R2.5 and C1.5
• Counterbalance trucks with 3 and 4 wheels from the J series
• K Series medium and high lift order pickers

The Solution

Globally successful with a strong local dealer network, POLI-TAPE has found a reliable partner in Hyster. Kowalski Transportgeräte GmbH is one of the 17 local dealers in Germany, Austria, and Switzerland. Together, the two companies developed a comprehensive solution with individually configured forklifts of all classes including fleet management via Hyster Tracker and 24/7 service.

Today, the fleet supports all processes between warehouse and manufacturing with 40 rented Hyster forklifts. To find the right solution, Kowalski held many discussions on-site. Every specific customer requirement was analysed, understood, and implemented in individual configurations. Today, the fleet optimises efficiency in a confined space with maximum comfort for drivers.

Manoeuvrable pallet trucks supply the lines with basic components such as film, glue and paper in the area-efficiently designed production. At the end of the line, suitable forklifts take over the sensitive goods, cut and wrapped, for internal transport to the warehouse. Industrial trucks maintain the steady flow until everything is packed and ready for dispatch.

The process is labour-intensive. Only a few things can be automated. The variety of load carriers need people. Well-trained warehouse workers are hard to find in empty labour markets. Equipment that makes work easier is an important criteria in the job for many. Hyster meets these demands with manoeuvrable vehicles that are easy to control.

Hyster can cover all requirements with more than 140 different models at POLI-TAPE. Among others, small high-speed trucks supply the production. Manoeuvrable pallet trucks bring goods efficiently from A to B. Counterbalance trucks safely take over even heavy and bulky items with the best all-round visibility. Driver assistance systems additionally minimise damage to vehicles and goods. Especially in high-bay warehouses, sensors and cameras facilitate precise storage and retrieval at any height.

The logistics operation gets everything from a single source, including maintenance and service. At an operational level, the fleet manager at Kowalski has a contact person and a permanent mechanic who knows the fleet. In the background is Kowalski’s 18-strong service team, including an in-house workshop, a well-stocked spare parts warehouse, and fast deliveries from the Hyster central warehouse in Nijmegen, the Netherlands, 50km away. There are hardly any breakdowns.

Hyster Tracker brings additional operating efficiency. The telematics solution provides all the necessary data in real-time. For example, the fleet manager recognises critical points in the process and can train drivers in a more targeted manner. Key data helps control predictive maintenance. Before each start, the system has the capability to check whether the driver is sufficiently trained and capable of operating the truck. All necessary checks are carried out via user-friendly displays, which also provide alerts during operation, for example in the event of excessive speed.

“If there is high downtimes, even the best forklift truck is of no use. That’s why we rely on the solid brand-name trucks from Hyster. They are as robust as a Volkswagen with premium service from a single source.”

The Results

Compared to the past, the Hyster fleet has significantly reduced unplanned downtime. Wear and tear on the vehicles and time-consuming transport damage have also decreased. Efficiency has increased. The warehouse staff are more satisfied. The ergonomically designed vehicles not only help protect operators’ comfort and wellbeing, but also relieve the time pressure caused by unnecessary damage.

“With comfortable hand movements and perfect all-round visibility, I can also store and retrieve goods precisely from above,” says a warehouse worker. “The similar handling of all Hyster trucks also makes the changeover easy in the fast-paced daily business.”

POLI-TAPE has completely digitalised its fleet management via the Hyster Tracker. Transparency in fuel consumption and driving behaviour enables targeted improvement measures. Clear key figures in real-time allow for predictive maintenance. For POLI-TAPE, breakdowns have been reduced to a minimum.

“Hyster is the right choice. We have a modular system that meets every need. The units can be optimally adapted to our requirements and individually configured. Service is available around the clock. Unnecessary downtime and dissatisfied employees due to poor equipment are a thing of the past,” said Peter Wieland, Supply Chain Manager of POLI-TAPE Klebefolien GmbH.

 

 

At a time when companies are focused on keeping business costs to a minimum, a strict materials handling equipment maintenance and servicing regime is more important than ever, says Toyota Material Handling UK Ltd’s Service Sales Manager, Andy Pritchard.

Regardless of whether your business operates a single pallet truck or a large fleet of varied materials handling equipment, when sourcing forklift trucks it is important to deal with an organisation that has the infrastructure in place to guarantee the highest levels of lift truck service and maintenance support.

A regular servicing and maintenance regime is the best way of preventing significant truck downtime – and all the cost and disruption to a business that can entail. And, with repair costs for serious truck damage rising, a commitment to forklift maintenance and servicing is becoming more important than ever.

Toyota offers a range of after-sales care and support packages to suit the business needs of companies of all sizes operating in all industry sectors. For example, the ‘full service’ package involves a comprehensive parts and labour plan that covers preventative maintenance, breakdowns and parts used in service and breakdown repairs.

Most Toyota customers agree a planned service contract at the time that they buy or rent their truck or trucks. With the support of Toyota’s dedicated after-sales development team to guide them through the various options available, Toyota customers can choose their plan with complete confidence, safe in the knowledge that it will keep their trucks safe and in good working order to ensure that they get the most out of their materials handling equipment at all times.

Customer satisfaction is our number-one priority and we do everything we can to meet our customers’ needs and expectations. Since service is a key differentiator, it’s important to us and, of course, our customers, that we carry out preventative maintenance and any repairs that are required quickly and efficiently.

We apply the Toyota Service Concept, a structured approach to optimise our services that is based on 12 key values that include ‘Poka Yoke’ – a Japanese term that means ‘mistake-proofing’ or ‘inadvertent error prevention.’ For example, by constantly upgrading the quality of spare parts and checking them before shipping, we ensure that the right part will be delivered in time.

Across the UK we employ some 600 technicians. We guarantee to respond to a customer’s request for assistance within four working hours and have a 96% first time fix rate. We aim to get things right the first time so we make sure parts are available when they are needed. And, we service any make of truck – not just Toyota models – which is essential for those clients that operate mixed fleets.

95% of spare parts are always available and any Toyota parts that are not held in stock are delivered within 24 hours. The genuine Toyota parts used are designed and tested to be safe and to prevent equipment failure, which means downtime risk and repair costs are lower and a client’s operational efficiency and, therefore, profitability is increased.

 

 

IMHX 2022 will see the launch of Narrow Aisle Ltd’s latest Flexi ACiON (pictured) and Flexi LiTHiON VNA truck ranges.

With all drive, hydraulic and power-steering functions digitally controlled, the trucks in the Flexi ACiON (lead acid battery-powered) and Flexi LiTHiON (lithium-ion battery-powered) collections are described as a ‘tour de force’ in articulated lift truck drivability, reliability and battery energy saving.

The introduction of digitally controlled motors for steering and all other key functions delivers a more integrated truck performance and results in greater reliability, more pallets moved per hour and significantly reduced maintenance costs.

Full digital control means that all models are ultra-energy efficient: regenerative energy produced every time the truck’s mast is raised or lowered, as well as during forward and reverse travel and by movement of the steering wheel, feeds back to the battery to maximise the time that the truck can perform between battery changes or charges.

In addition, noise levels are significantly reduced and steering and mast control operations – whether using the lift/lower or sideshift functions – are carried out with optimum precision at all times.

But it is not just ‘under the bonnet’ where enhancements have been made: when developing the new Flexi ACiON and Flexi LiTHiON range, Narrow Aisle’s design team sought to produce the ultimate driver-friendly articulated forklift trucks on the market.

All aspects of operator visibility have been improved. For example, the trucks’ HiVis overhead guard has been redesigned and reconfigured to ensure perfect upward visibility of the forks and the load when stacking. The guard also features a soft grey finish that is proven by optometrists to be ‘easy on the eye’ to further aid the operator’s through vision.

Clear forward visibility is ensured by the use of three-stage lift masts, which feature four-lift cylinder technology that not only delivers full fork vision to make pallet entry clear and straightforward, but also provides class-leading lateral stability.

The latest Flexis have been developed to make order picking duties easier and safer. For instance, the ‘Halo bar’ feature provides the most comfortable single-handed action to mount or dismount the truck during intensive applications. All models are fitted with a fully weight adjustable premium seat which, combined with the trucks’ adjustable steering column, reduce operator fatigue – even during the longest shifts.

Models in Narrow Aisle’s Flexi ACiON and Flexi LiTHiON Truck ranges can operate safely and efficiently in aisles down to just 1.6m wide and can lift loads weighing up to 2.5 tonnes to heights of 14m. The Flexi’s 220° articulation feature that makes turning easier and faster is incorporated into all models in the range to ensure more pallet movements per hour.

In addition, visitors to the Narrow Aisle stand will be able to see the unique FlexiPick layer order picking system. The FlexiPick allows users to take advantage of the increasingly popular layer quantity FMCG order assembly concept. It allows retail customers to order boxed products on a larger quantity with up to five different products (SKU’s) per pallet, without the need to invest in the kind of high fixed cost automated handling technology that previous layer picking systems have relied upon.

Thanks to its articulated chassis design, the FlexiPiCK system is the perfect platform for layer picking technology. When using the FlexiPick full pallet loads of the most popular layer quantity products in the DC are arranged in an aisle format at ground level and with assembly stations positioned at the end of each aisle. The FlexiPick’s integrated hydraulic arms carefully lift single or multiple layers of product and deliver each individual layer picked to the assembly station where a load is made up of full layers.

The FlexiPiCK system works comfortably in access aisle of less than two metres – which hugely reduces the floor space footprint required. Furthermore, steel guidance rails are not required for the system to function at faster picking rates, which allows a more flexible load assembly aisle layout with more product options included.

Layer picking has become increasingly popular in the USA, where it is seen as a solution to manual handling stress injuries on high volume case picking operations. By picking orders in layers, FMCG companies can reduce case quantity picking costs by a huge amount – which provides opportunities to offer reduced costs to clients that place larger orders in layer quantities.

With its headquarters, design and manufacturing facilities in the UK, Narrow Aisle Ltd has supplied over 10,000 Flexi articulated forklift trucks to users throughout the world and has a global network of over 65 authorised distributors.