Why Innovation Matters More Than Ever18

PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION, WAREHOUSING AND MANUFACTURING

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May 2018 WHY INNOVATION MATTERS MORE THAN EVER 18

SPECIAL REPORT Top 20 system suppliers 26

BEST PRACTICES Re-labeling your warehouse 32

INFORMATION MANAGEMENT ERP WMS 38

EQUIPMENT REPORT Automated storage 44 High-Density Inventory Management and High-Speed Order Fulfillment

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Modex 2018 sees record attendance MODEX 2018, the 4th edition of the expo, saw a 25% jump in the number of registrations for a total of 30,944 attendees.The net square footage also set a record, topping 283,025 square feet and featuring 925 exhibits. According to a release from show organizer MHI, the dominant trend surrounded digital supply chain solutions including automation, robotics, artificial intelligence, Detection System; Best IT Innovation: Yard Management autonomous vehicles, augmented reality, the Internet of Solutions for Eagle Eye Yard Management Software Things and data analytics. On Industry Night, MHI also The MHI Young Professionals Network (YPN) honored announced the winners the 2018 MHI Innovation Awards: recipients with its annual awards: Best New Product: The Raymond Corp. for Raymond Mentor Award: James J. Radous III, UniCarriers Virtual Reality Simulator; Best Innovation of an Existing Americas; Outstanding Young Professional: Brian C. Product: ELOKON GmbH for ELOshield - Proximity Neuwirth, UNEX Manufacturing. Tompkins Robotics partners with RightHand Robotics UNEX Manufacturing AT MODEX, Tompkins Robotics and RightHand Robotics acquires SpeedCell announced a collaboration that will combine a portable UNEX MANUFACTURING automated sortation system with announced the acquisition of robotic piece-picking systems. SpeedCell Storage Systems of Tompkins Robotics offers the Zeeland, Mich., at Modex. patented automated sortation SpeedCell’s dynamic storage system, t-Sort, which performs solution products, paired with much like a conventional tilt tray or Unex’s Span-Track carton flow and Flow Cell product lines crossbelt sorter, but with completely add high-density storage to the pick, put or assembly line. SpeedCell compartmentalized hanging shelves independent robots. The modular adapt existing pallet rack structures to accommodate an solution is intended to help retailers grow e-commerce increased number of product pick faces. The columns platforms or leverage existing store footprint for omni-channel. of shelves are suspended from the pallet rack on a track RightHand Robotics offers RightPick, a solution consisting system that permits them to slide side to side for access of artificial intelligence software and robotic picking hardware. up to seven rows deep. It’s intended to reduce costs and improve reliability of the fulfill- “It complements our pick, put and place storage ment process for grocery, apparel and more. solutions for manufacturing and distribution right up The news follows Tompkins’ announcement of a partnership to the last mile,” said Mark Neuwirth, vice president with SI Systems that will see the t-Sort paired with SI Systems’ of business development at UNEX. “We now have a portfolio of robotic A-frame dispensing technologies. better solution for those items whose throughput simply requires a better pick and storage medium then settling RightHand also announced a partnership with Vecna Robotics, for traditional static shelving.” a provider of autonomous collaborative mobile robots.

MHI study highlights technologies driving next-generation supply chains A PANEL at Modex discussed the survey of more than 1,100 supply chain artificial intelligence; driverless findings of the “2018 MHI Annual professionals. The keynote panel was vehicles and drones; wearable and Industry Report,” citing 11 key moderated by Scott Sopher, principal mobile technology; inventory and technologies driving next-generation with Deloitte Consulting’s supply chain network optimization; sensors and supply chains while naming top barriers practice, and George W. automatic identification; Cloud such as cybersecurity and framing the Prest, CEO of MHI. computing and storage; and business case for the technologies. The 11 key next- 3D printing. This is the fifth in a series of reports generation technologies Cloud computing leads MHI has developed with Deloitte include: Blockchain; in adoption, the 2018 study Consulting. Titled “Overcoming robotics and automation; found, with a 57% adoption Barriers to NextGen Supply Chain predictive analytics; rate which is expected to Adoption,” the study is based on a Internet of Things; reach 91% in five years. mmh.com MODERN MATERIALS HANDLING / M a y 2 0 1 8 3

VOL. 73, NO. 5

® PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION, WAREHOUSING AND MANUFACTURING

60 seconds with... John Hill Director, St. Onge

DEPARTMENTS & COLUMNS Cover illustration: Phil Foster COVER STORY 3/ Upfront 18 Why innovation matters 7/ This month in Modern more than ever 14/ Lift Truck Tips: Mobile computing This is no longer your father’s materials handling industry. 16/ Packaging Corner: Containers Leading suppliers are developing a culture of innovation, 50/ Modex Wrap Up leading to new solutions for new challenges. 58/ Productivity Solutions 62/ Supplement: Automation Survey 76/ Focus On: Dock Equipment FEATURES 80/ Products SPECIAL REPORT 82/ 60 seconds with... 26 Top 20 system suppliers Across the globe, the industry achieved record-smashing growth. NEWS BEST PRACTICES 9/ Modex 2018: Trying to figure it out 32 How to survive warehouse re-labeling 10/ International Forklift of the Year Award Who wants to re-label the warehouse or distribution center? No one, winners announced most likely. But it’s got to be done, and now more frequently than 11/ Orbis Corp. acquires Response ever. Here’s a best practices guide to get you through the process. Packaging information management. 12/ Some use of Cloud solutions now INFORMATION MANAGEMENT the norm 38 The path forward for ERP WMS There’s nothing static about warehouse management systems from enterprise resource planning suppliers. The user base is expanding at a notable clip. And, next-generation supply chain technologies from Modern Materials Handling® (ISSN 0026-8038) is published monthly the Cloud to data analytics and smart glasses are in their future. by Peerless Media, LLC, a Division of EH Publishing, Inc., 111 Speen Street, Suite 200, Framingham, MA 01701. Annual subscription rates for non-qualiﬁ ed subscribers: USA $139, Canada $219, Other Interna- EQUIPMENT REPORT tional $269. Single copies are available for $20. Send all subscription inquiries to Modern Materials Handling, PO Box 677, Northbrook, IL 44 Warehouse basics: Automated storage 60065-0677 USA. Periodicals postage paid at Framingham, MA and additional mailing ofﬁ ces. POSTMASTER: Send address changes to: systems embrace new roles Modern Materials Handling, PO Box 677, Northbrook, IL 60065-0677. Reproduction of this Distribution and fulfillment applications are looking to automated magazine in whole or part without written permission storage to do what it does best—plus a little bit more. of the publisher is prohibited. All rights reserved. ©2018 Peerless Media, LLC. mmh.com MODERN MATERIALS HANDLING / M AY 2 0 1 8 5 Fast. Flexible. Scalable.

EDITORIAL OFFICES 111 Speen Street, Suite 200 MICHAEL LEVANS Framingham, MA 01701-2000 GROUP EDITORIAL (800) 375-8015 DIRECTOR

Michael Levans GROUP EDITORIAL DIRECTOR [email protected] Bob Trebilcock Investment and innovation EXECUTIVE EDITOR [email protected] Noël P. Bodenburg are alive and well EXECUTIVE MANAGING EDITOR [email protected] f you were walking with me during Modex skilled labor force, we’re going to continue to Josh Bond last month, you would have heard me feel that energy to invest and innovate. The SENIOR EDITOR [email protected] Iutter the words: “This may be the busiest challenges are real, the innovative solutions are Sara Pearson Specter trade show fl oor I’ve ever seen.” Aisles available, so now organizations are exploring EDITOR AT LARGE [email protected] were packed, sometimes impassable, and how it all fi ts together.” Roberto Michel excitement was in the air. This event was This month in Modern, we fi nd a couple early EDITOR AT LARGE [email protected] simply the embodiment, the pure validation indications that this positive wave will continue, Bridget McCrea of a few themes we’ve been discussing in the and the buzz at Promat 2019 could be even EDITOR AT LARGE pages of Modern over the past 18 months. louder. Starting on page 62, editor at large [email protected] First and foremost, investment and the Bridget McCrea puts context behind the fi ndings Jeff Berman GROUP NEWS EDITOR intention to invest in equipment, software of Modern’s 2018 “Usage and Implementation [email protected] and automated solutions that we’ve seen of Warehouse and DC Automation Solutions” Wendy DelCampo ART DIRECTOR illustrated in our reader survey numbers over that was fi elded in January to assess usage and [email protected] the past year is, indeed, real. I lost count purchase intentions for automation systems. Polly Chevalier ART DIRECTOR of how many times suppliers told me they “The bottom line is that companies certainly [email protected] had been engaged in more “real business expect to spend more on materials handling Daniel Guidera conversations” than in any show in years past. equipment and solutions than last year,” says ILLUSTRATION [email protected] Second, the spirit of innovation is alive and McCrea. “And a key driver is certainly the labor Kelly Jones well. This Modex will perhaps be best known shortage. As it becomes more diffi cult to recruit PRINT/ONLINE PRODUCTION MANAGER for displaying the software, automation, sensors and retain, organizations believe automation [email protected] and robotics designed for better connecting will help them manage the shortage while Brian Ceraolo the nodes of the supply chain—showcasing the maintaining productivity and profi tability.” PRESIDENT AND GROUP PUBLISHER [email protected] pieces of the digital network that will speed And, as executive editor Bob Trebilcock

PEERLESS MEDIA, LLC commerce outside the four walls, and streamline reports this month, as those challenges mount, www.peerlessmedia.com work for a diminishing labor force inside. the vendor community is saying, “bring it on.” Kenneth Moyes When I caught up with Norm Saenz, Starting on page 18, he offers a terrifi c follow PRESIDENT AND CEO EH PUBLISHING, INC. managing director of St. Onge and a frequent up to his 2017 piece on the role of innovation MAGAZINE SUBSCRIPTIONS contributor to Modern, he was equally as in materials handling technology development. Start, renew or update your FREE magazine subscription inspired with the vibe and just as bullish on the “From my reporting and experience at Web: mmh.com/subscribe Email: [email protected] near future of the materials handling market as it Modex, I discovered innovation is alive and well Phone: 847-559-7581 Mail: Modern Materials Handling begins to play a bigger role in the digital supply in our market,” says Trebilcock. “Large players P.O. Box 677 Northbrook, IL 60065-0677 chain network that so many organizations are and startups are dedicating resources to For reprints and licensing please contact Brett Petillo striving to understand and implement. innovation teams to look for how to apply 877-652-5295, ext 118 [email protected]. “There are a few elements at work,” Saenz tomorrow’s technologies to their solutions—and ENEWSLETTER SUBSCRIPTIONS told me. “As long as we have the e-commerce it’s one of the reasons why I fi nd this to be the Sign up or manage your FREE eNewsletter subscriptions at fulfi llment challenge mixed with the lack of a most exciting time in my career.” www.mmh.com/enewsletters.

Ofﬁ cial Publication of peerlessmedia.com Member Member of Winner Jesse H. Neal Certiﬁ cates of Merit for Journalistic Excellence peerlessmedia.com mmh.com MODERN MATERIALS HANDLING / M AY 2 0 1 8 7 Connect. Adapt. Transform.

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ANALYSIS Modex 2018: Trying to figure it out The new technologies on display in Atlanta were exciting, promising and confounding for materials handling customers faced with a new set of distribution challenges.

BY BOB TREBILCOCK, EXECUTIVE EDITOR

IT’S BEEN SAID THAT AMAZON IS DEVELOPING—or has can’t modify them to keep up with new expectations.” developed—the ability to pre-position inventory in antici- In other words, they’re trying to fi gure it out. It seems pation of our orders. In short, they’re trying to fi gure out to me that materials handling customers are dealing with what we want before we know we want it. multiple and opposing challenges. On the one hand they That’s what I was thinking about during Modex 2018. don’t want to go too far into automation, given all the Near the end of day one, I asked J.J. Schambow, the new technologies being introduced—everything from business development executive for enVista, what booth robotics, to sensor technologies, to a myriad of goods- visitors were looking for. Her answer was quick and short: “They’re just trying to fi gure it out.” On Tuesday, I met with Pieter Krynauw, the new president of Honeywell Intelligrated, who talked about the idea of the connected supply chain, one in which workers are connected inside the DC, the DCs are connected across a network, and they’re all connected to processes happening outside the four walls and across the supply chain. “Industry has not come to grips with what this means to their supply chains,” Krynauw said. I posed the same question—What are our customers looking for—to Steve Simmerman, the senior alliance director for JDA, and Scott Deutsch, the North American president of Ehrhardt + Partner (E+P), and got similar to-person solutions. They don’t want to invest today in a answers. “Help,” was Simmerman’s one word reply. solution that will be outdated tomorrow. Deutsch, meanwhile, said he’d given a standing-room- They don’t want to be left behind either. They see only presentation on upgrading your warehouse manage- these new technologies and wonder how they might be ment system (WMS), having no idea how big a crowd applied in their operation. And, there’s the labor issue. to expect. “Those I talked to after said they had legacy As Deutsch pointed out, in too many facilities, those with systems managed for years by someone who was ready to experience are retiring with no one coming up behind retire,” Deutsch said. “They don’t have anyone else who them. Many companies are gambling on automation to knows how to keep them running and they’re afraid they alleviate the problem. mmh.com MODERN MATERIALS HANDLING / M AY 2 0 1 8 9 It’s an exciting time for those of us who have been around the industry for years, when innovation was about running faster conveyor and sortation speeds. As a Dematic executive pointed out when he showed me a new goods-to-person layout, the system is designed to minimize the amount of conveyor. At the same time, like everyone else, I’m trying to fi gure it out.

LIFT TRUCKS International Forklift of the Year Award winners announced ssi-schaefer.com AFTER SIX MONTHS OF TRIAL AND SELECTION, the jury of the International Forklift of the Year (IFOY) Awards has announced the winners from among 12 IFOY-nomi- nated devices, components and solutions. Over the course of one week in the beginning of February, the testers lifted, drove, measured, stored and discussed in the jury sessions. More than 100 guests from 18 nations, including various test teams as well as more than 30 jurors and accredited consultants from industry, logistics services, media and science, traveled to CeMAT in Hannover to follow the tests live. “It was the toughest and most narrow decision ever made at the IFOY Award,” said Anita Würmser, chair-

woman of the IFOY jury at the celebration during the CeMAT opening ceremony. “The IFOY audit has shown that all ﬁ nalists are far ahead of their competitors in terms of quality, innovation and practicability, not only on paper yet also in practice.” Witron Logistik + Informatik GmbH, Parkstein, Germany, triumphed in the premium class of “Integrated Warehouse Solutions” for its Migros Distribution Center Suhr AG in Switzerland. According to an IFOY release, Witron developed an integrated omni-channel solution merging the volatile small volume order picking with the Migros branch business. The new RX 20 from Hamburg-based Still GmbH was voted best truck of the year. The jury noted it is the only

mmh.com truck type that can drive with either circuit A or B batteries and use both lead-acid and lithium-ion batteries. Two vehicles were named Warehouse Truck of the Year: The ECE 225 from Jungheinrich AG and the PROFESSIONAL GRADE Wegard Trail from the Hamburg startup Wegard GmbH. The ECE 225 with easyPILOT Follow is a semi-automatic PALLET CONVEYOR solution by which the order picker automatically follows his operator. The Wegard Trail is a modular tugger train with autonomous and electronically steered axles. Jungheinrich won a second IFOY Award in the “Special of the Year” category with the cross-technology SLH300 battery charger for industrial trucks. According to the jury, the plug and play solution for charging conventional lead- acid and more efﬁ cient lithium-ion batteries offers advantages for mixed ﬂ eets or during the switch from lead-acid to lithium-ion technology.

PACKAGING y chain Orbis Corp. acquires Response Packaging is Orbis Corp., a North American leader in reusable packaging and part of Menasha Corp., announced that it Automated palletizing is a key to controlling suppl acquired Response Packaging in Piedmont, S.C. cost. Professional Grade Pallet Conveyor equipment designed to support this challenge.Grade Pallet Conveyor Founded in 2009, privately held Response Packaging conceptualizes, designs, prototypes and manufactures LEWCO Professional Pallet Transport, Pallet Transfers, reusable custom dunnage and fabricated steel rack solu- equipment is designed to help facilitate: • Pallet Dispensing, Pallet Stops, and Case Handling. tions. Included in the acquisition are design, testing and Pallet Register, manufacturing facilities in Piedmont, and Greenville, S.C.; Auburn Hills, Mich.; and León, Mexico. Response Packaging will operate and be branded as a part of Orbis. “This acquisition brings us talented people, effi cient plants and strong capabilities in geographic areas CHAIN DRIVEN where Orbis wants to grow,” said Bill Ash, president of LIVE ROLLER Orbis Corp. MULTI-STRAND CHAIN CONVEYOR Response Packaging has 245 employees in the U.S. WITH POP-UP PALLET SIDE LOADED PALLET CENTERING DEVICE and Mexico and serves the automotive and industrial mar- STACKER/DE-STACKER WITH MULTI-STRAND CONVEYOR kets with highly engineered custom dunnage designed CHAIN your Professional Grade Pallet for part protection. Additionally, it specializes in fabricated Our knowledgeable your application requirements. steel rack and dunnage systems for the safe and effi cient Contact us today to discuss solution, built to the transport of vehicle components in the supply chain. Conveyor equipment “Orbis has been pursuing a strategy to expand its staff of Application Engineers will assess needs and recommend a cost-effective custom business to serve customers with a broader port- highest industry standards. folio of solutions,” said Jim Kotek, president of Menasha Corp. “The acquisition of Response Packaging supports this objective by adding complementary capabilities and VISIT US AT PACK EXPO BOOTH E-9339 establishing a manufacturing presence in the Southeast and expanded capabilities to meet our customers’ needs in Mexico.” 706 Lane Street | Sandusky,WWW.LEWCOINC.COM Ohio 44870 419.625.4014 mmh.com TECHNOLOGY adoption rate for Cloud solutions. chains. Cloud computing ranks highest Some use of Cloud That data point, as well as solutions in terms of adoption, reaching a 57% solutions now the norm evident on the show fl oor, point to adoption rate this year. how Cloud solutions increasingly are When asked about plans for fi ve THE 2018 MHI INDUSTRY REPORT part of user strategies. years from now, 91% of the more released at Modex has many The MHI report examines industry than 1,100 supply chain professionals interesting fi ndings, including the trends for next-generation supply surveyed say they will have introduced Cloud-based systems. That means soon it will be rare for a company with supply chain operations to not have at least some Cloud-based applications. There were numerous Modex exhibitors who use Cloud services as the primary option for deployment. While analyst data shows that within the warehouse management system (WMS) market, the installed base of end user sites is largely deployed on servers managed on site, many other solutions are used in the industry. Transportation management system (TMS) applications, for example, increasingly are offered as Cloud solutions, even as more WMS vendors focus on Cloud offerings. Many other types of Cloud-based applications are relevant to warehouse and logistics operations, especially in new niches. For example, The Raymond Corp. is known for its lift trucks, but it also offers its iWarehouse fl eet management system, which can be deployed in the Cloud. At Modex, John Rosenberger, director for iWarehouse, said Raymond has focused on building a comprehensive suite of software that can be easily deployed to optimize lift truck fl eet and warehouse operations. The suite spans various key functions including telematics, certifi cation management, labor management, real-time locating system (RTLS) concept capabilities, support for automated processes, and a Web portal for visualizing trends that make it unnecessary to cobble together point solutions, Rosenberger said. “You can bring together all these functions 12 M AY 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com in one integrated solution to get a offerings at Modex point to an IT on-premise WMS because a vendor complete picture of what’s going on foundation where many relatively new offers a Cloud option, but for many in your warehouse and make your functions can be quickly brought into newer functions that weren’t needed or processes more effective,” he added. place with Cloud deployment, even perhaps not even envisioned when Modex exhibitor Cloudleaf offers a while key existing systems remain WMS was deployed, the Cloud is Cloud-based supply chain visibility and on-premise. Few companies are going becoming the go-to means for sensor data platform, whose use by an to ditch an adequately working, deployment.—Roberto Michel unnamed pharmaceutical company for “cold chain” monitoring is highlighted in the MHI report. According to Nitesh Arora, head of marketing for Cloudleaf, its platform is completely Cloud- Container based, performing edge computing on sensors and gateways without an edge Exceeding Expectations unloading server on site, simplifying deployment. “Our patented technology allows us to continuously track every sensor within four walls as well as outside and Automate your inbound process? in-transit,” Arora said. “Infrastructure Please contact [email protected] footprint is very low and the sensor batteries last three to fi ve years.” Another Modex exhibitor, TEC- SYS, introduced a “last-mile” delivery management solution that can be deployed in the Cloud, said Bill Den- bigh, director of logistics product marketing at TECSYS. The solution aims at giving regional distributors and logistics providers a set of delivery management tools similar to those that major parcel couriers can offer to customers, Denbigh said, in a Cloud-deployable solution pre-integrated with TECSYS’s WMS, or that can integrate with other WMS solutions. The functions in TECSYS’s solution spans delivery tracking, dock management, dispatching, driver management, and home delivery functions such as scheduling of “white glove” services like unpacking and set up of equipment. While TECSYS can deploy the system on premise, Denbigh believes the Cloud option will be preferred because it is a quick, less complicated way to put in place the last www.copalhandlingsystems.com ’s-Heerenberg mile functions organizations need to The Netherlands +31 314 66 78 55 keep up with major online competitors. The MHI study and the software mmh.com MODERN MATERIALS HANDLING / M AY 2 0 1 8 13 LIFT TRUCK TIPS

All features great and small No two applications are the same, so mobile computer deployments should be equally detailed.

By Josh Bond, Senior Editor

he quest to be more productive, efficient and profit- tant as those between the device and forklift. In addition able is driving the pursuit of technologies that help to automatically blacking out device screens during travel, T get the most transactions out of a warehouse and intelligent setups feature better battery power manage- its workers. No data or details are too small, and makers of ment—whether the device draws power from an electric mobile computing solutions are increasingly pressured to or internal combustion forklift. For example, the device deliver not just hardware, but operational outcomes. will automatically engage a backup battery during a power “We are more required to be true solution providers disruption, like a forklift battery change to preserve the because partners and end-users de- device’s connection to data systems. mand it of us,” says Eric Miller, CEO “Telematics is big, and it’s not just of JLT Mobile Computers. “More about connections with the warehouse services revolve around the balance management system (WMS) and inven- of hardware and infrastructure, soup tory transactions,” Miller says. “It’s also to nuts, from custom cables and about driver safety, efficiency, fuel con- mounts to data management, to de- sumption, predictive forklift maintenance ployment and asset management.” and more. All forklift manufacturers run In this environment, simple perfor- a more intelligent forklift, and I think mance specs are a small step toward computers in the dashboard will become optimally pairing a mobile device with more and more standard.” an application. The complete journey, Miller predicts an embedded onboard Miller says, requires exhaustive fact tablet could handle the maintenance side finding. High-level concerns center of the house, tracking data like forklift bat- on: whether devices can reliably run tery temperature, hydraulic pressure levels through a full shift or 24/7 if needed; and activity. Mounted mobile computers, whether IT infrastructure can support continuous connec- meanwhile, will continue to provide a window into the tivity and seamlessly hand off data between departments; WMS to drive order pickup, placement, shipping, receiving and operating system security and support. Day-to-day and other similar types of transactions. concerns include: when and how often a forklift operator “I see those things overlapping, yes, but not for another might need to re-position or remove a vehicle-mounted two to four years, when a forklift comes with a device that terminal; how to minimize asset and worker downtime by connects to the WMS,” he says. “Already, a mobile streamlining maintenance; and how individual workers computer has so many sensors, gyroscopes, accelerom- might benefit from touchscreens or keyboards, or larger eters, RFID and more, and the question is: How do we cap- and brighter screens. ture data, and what do we do with it? The first step is to “People are talking about augmented reality and virtual make the forklift an intelligent device and a data collector reality, but how about we start with a screen the worker can so you can better manage the fleet and its drivers.” actually see?” Miller says. “One of the most overlooked aspects is how easy it is for an aging workforce to see and interact with a device.” Josh Bond is Modern’s senior editor and can be reached at Interactions between workers and devices are as impor- [email protected]

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Industrial wire containers find use in new applications Embraced by a variety of industries beyond traditional materials handling, wire containers are durable and provide visibility.

By Sara Pearson Specter, Editor at Large

ong used by manufacturers for handling baskets for disposal of dunnage, cardboard and heavy, dense components—like those stretch wrap when they are unpacking pallets L in the automotive or tool and die indus- and cartons of received product. After having tries—industrial wire containers have been repeatedly replaced lightweight containers that adopted by other industries as well, often in couldn’t handle the abuse, they invested in a surprising applications. more durable solution.” “We have a fitness apparel brand that uses our Made of robotically welded steel with a powder WorldTainer industrial wire containers to sort and coat or galvanized finish, the WorldTainers come organize specific items by SKU and by size,” says in a range of standard dimensions—from 20 x 32 Richard Willix, director x 22 inches to 40 x 48 x 42 of sales at Worldwide inches. The containers can Material Handling be customized with differ- (WWMH). “Not only do ent mesh types and with they use them internally dividers to organize work- to store inventory, but in-process parts or inven- they also ship them tory. Other options include to and from stores in handles for smaller models a closed-loop system or casters for larger models for replenishment, as that are pushed from one the containers collapse point to another. when empty to reduce “Additionally, we can shipping costs.” add a wire mesh lid to But why would a pur- secure the contents with veyor of lightweight athletic garb choose a con- locks,” Willix says, noting that a sporting goods tainer engineered to hold a maximum capacity of retailer secures rifles and ammunition this way, 4,000 pounds? “Unlike reusable plastic containers while a special events caterer does the same with with solid sidewalls, wire mesh provides high vis- liquors. “It surprises us all of the ways operations ibility, allowing associates to see what’s inside for come up with for using them; they really are the quick identification,” Willix explains. duct tape of containers.” “They’re also far more durable than cardboard,” adds Joel Eckberg, who handles major account sales for WWMH. “It may seem like Sara Pearson Specter is an editor at large with Modern overkill, but several retailers use them as waste and can be reached at [email protected].

16 M a y 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com 2018 MHI INNOVATION

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MODERN cover story MATERIALS HANDLING INNOVATION matters more than ever This is no longer your father’s materials handling industry. Leading suppliers are developing a culture of innovation, leading to new solutions for new challenges.

BY BOB TREBILCOCK, EXECUTIVE EDITOR

ohn Hill knows a thing or two about Hill has not rested on his laurels. Still a director technology innovation. In a career that at St. Onge, he recently attended a conference on spans 50 years, Hill was at the forefront of automatic identification that brought together more J the development of industrial applications than 400 experts to Google’s headquarters in Sunny- for bar code scanning and radio frequency vale, Calif. When he looks at the new mechanical identification and the first warehouse management and technology solutions coming to market, he sees software systems (For more on Hill, see p. 82). the seeds planted back in the 1970s and 1980s now There’s a reason he remembers that the first bearing fruit. implementation of bar code scanning outside of “We’ve finally come to where we all thought point of sale in grocery and retail was in October in our naivete that we’d be by around 1980,” Hill 1971 at Buick’s Plant 10. “I carried the 50-pound says. “Nothing we’re doing today, even artificial scanner into Buick to give them the demonstration,” intelligence, belies what we thought we could do Hill recalls. more than 40 years ago. It’s just that we didn’t have Phil Foster

mmh.com MODERN MATERIALS HANDLING / M a y 2 0 1 8 19 MODERN cover story

to existing solutions and technologies. “To do true innovation that results in exponential innovation, you have to move the pace of innovation.” To make that happen, he adds, requires a need in the market, competent people and resources. To that end, Tompkins created a 12-member innovation team that meets on a regular basis to ask: What is a need that has to be filled? He also created an innovation fund so competent people would have the resources available to explore solutions that might fill the need. An example of innovation in action is the evolution of a robotic shipping sorter technology that Tompkins licensed from China. “We could’ve made modifications to it, which would A ping pong table in a Tompkins’ engineer’s garage was the inspiration for a robotic have been linear, but instead, we sortation solution for use in e-commerce fulfillment and, potentially, in the backrooms of retail stores. created software that turned it into a unit sorter that allows us to do a batch the tools then that we have today.” several startups and smaller players, pick, sort and pack orders and then put So just what is materials handling just what innovation means to their it back on the same equipment to sort innovation? And, how does the organizations. Here’s what we learned. it to shipping,” Tompkins says. “That’s industry capture the lightning in a exponential.” The next step was to put bottle associated with innovators From linear to exponential it on a portable platform that could be like Apple and Google? Those innovation folded up and stored out of the way were questions we first asked in If you’ve ever seen any of the Farm- at the end of a shift, say in a big box the May 2017 issue. We set out to ers Insurance commercials, you know retailer’s backroom. The inspiration define just what innovation means the punch line: “We know a thing or came from a ping pong table in one to our industry along with how it is two because we’ve seen a thing or two.” of Tompkins’ engineer’s garage. “The approached at some of the leading Like John Hill, the same can be said of need,” he says, “was to make a portable OEM and system solution providers, Jim Tompkins, the chair and CEO of solution that could be rapidly deployed.” including Swisslog, Toyota Material Tompkins International as well as several Some solutions will be ahead of the Handling, Dematic, Honeywell startups springing from the Tompkins market, Tompkins concedes. “When I Intelligrated and Knapp Logistics organization. They include a third-party had the first meeting with the innova- Automation. (You can read “Materials logistics (3PL) provider for e-commerce tion team, I said this is not a consulting Handling Innovation (And Why It fulfillment, a robotics company and a project,” he recalls. “Our task is to read Matters)” on mmh.com). sensor-based organization to develop the things that aren’t yet on the page. We’re This year, on the heels of Modex, connected warehouse. going to fix problems that the client we thought we’d revisit the topic. But Tompkins defines two types of hasn’t seen yet.” instead of focusing on the household innovation: Linear and exponential. names in automation, we asked six “Linear innovation is just maintaining Change from the top down companies playing in the software the pace of where we’re at,” he says, Sometimes, you can teach an old dog or technology space, including which would include improvements a new trick. Zebra Technologies and

20 M a y 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com MODERN cover story

JDA are long-standing organizations a lift truck, person and order are in real driving the change from transactional to in what might be considered mature time. We’re looking at what’s going on in analytical and JDA created an innovation technologies: Automatic identification the warehouse and asking how that can center in Montreal where data scientists and printing at Zebra, and warehouse be rethought with sensor technology to are tasked with pure R&D as well as and supply chain management and gain economic value.” working with customers to develop point execution software solutions at JDA. Something similar is in motion at solutions that might then be folded into At the same time, those technologies JDA, according to Steve Simmerman, JDA’s suite of products. are at the intersection of established senior alliance director, who says that “In three to five years, I really solutions and the next-generation tools innovation is a key initiative from the believe we’re going to see changes in that are going to define tomorrow’s sup- CEO. “When he came in, he said our the physical infrastructure and soft- ply chains, such as sensors, artificial customers are demanding innova- ware managing DCs that no one has intelligence (AI), Big Data, the Internet tive solutions,” says Simmerman. “We imagined,” says Simmerman. of Things and Cloud computing. So, understand the physical movement how are they responding? In both cases, of goods. So, now, how can we use Applying AI to WMS a look to the future is being driven from machine learning, IoT and artificial Last year, we featured Lodge Manufactur- the top down. intelligence to make those systems more ing’s new distribution center in Tennessee. While it was a conventional DC in many respects, relying on lift trucks and pallet and shelf storage, one technology stood out: a Cloud-based, iOS native warehouse management system (WMS) from EVS that used artificial intelligence and machine learning to optimize processes and deliver tasks to an associate’s iPhone. The combination of Cloud-based computing, AI and an Apple operating system struck us as innovative at the time. What then, we wondered, does that term mean to Evan Garber, the CEO of EVS? “My phrase is that the supply chain starts with the warehouse,” says Garber. “If the velocity of inventory going in and out of your warehouse slows down, your supply chain slows down. If the warehouse can up its game, then the Zebra Technologies is looking at how the data collected by its conventional systems can now be used to connect assets across the enterprise. whole supply chain gets better.” Like Zebra and JDA, EVS has one “Our CEO doesn’t talk about us being efficient?” For example, how can plan- team working on product development a printer company but as being in the ning systems use social media news and support, and a second “Black Ops” enterprise asset intelligence space,” says events and weather data to create action team comprised of people whose job is Mark Wheeler, Zebra’s director of sup- plans for when an event like Hurricane to figure out where EVS should go next. ply chain solutions. “Our role is evolving Harvey is about to strike? “They work on prototypes and when they from being transactional to analytical: Both companies have created teams get to a certain percentage complete, we’ll Instead of being a system of record for dedicated to innovation separate from float trial balloons to analysts like Garter what happened in the warehouse, we’re traditional R&D: Zebra has a team work- or our customers for feedback,” Garber becoming a system of reality for where ing on Intelligent Edge Solutions that is says. “If they resonate, we bring them into

mmh.com MODERN MATERIALS HANDLING / M a y 2 0 1 8 21 MODERN cover story

Mobile robotics, like this solution from 6 River Systems, are emerging as an enabling technology for collaborative picking of small orders.

at Kiva Systems before the company was sold to Amazon in 2012. “When we founded the company in 2015, we decided that innovation means nothing unless it brings value to the customer,” Dubois says. “So, we asked: What’s the application that can be improved in the warehouse and that was pick-to-cart? Ultimately, our ah-ha moment was that it’s really a labor and a training issue. We decided not to go after the picking arm and replace the human, but create a solution that integrates the transport vehicle, the scanner, the WMS system, put-to-light and conveyor into one system that leads the picker through the warehouse.” He adds that in a 60-person company bringing a technology into a new space, “if you’re not innovating, you’re not doing your job. Our focus is innovating from the customer’s viewpoint.” In March of this year, we featured DHL Supply Chain’s initiative to bring new technologies into its e-commerce fulfillment operations. Along with robots from Locus Robotics and 6 River Systems, DHL was the normal product development cycle.” something we can learn from that? We’re also using smart glasses and augmented Garber’s team also looks at ideas they looking for relationships that aren’t visible reality from Vuzix for a pick-to-cart applica- have developed for one industry, such as to the naked eye or in reports to see if the tion. According to Lance Anderson, the the company’s roots in the food industry, system can make these kinds of links.” vice president of sales and marketing at and ask how they can be applied to other Vuzix and a veteran of traditional solution markets. As for AI, Garber says the WMS Startup innovation provider is looking at issues such as why In some respects, you could argue that Companies mentioned a stock out occurred to prevent it from startups, or firms bringing technologies happening again in the future. “If an such as robotics and smart glass vision in this article associate is supposed to pick 100 items at systems to a new market like distribution • 6 River Systems Bin A and there are only 90 items there, are by definition innovative. How then • EVS the WMS would just send the associate to do two startups approach innovation? • JDA another bin,” Garber says. “But what if we Jerome Dubois, co-founder and co- • St. Onge could also ask the system who was around CEO of 6 River Systems, a Massachu- • Tompkins International that bin space in the last two days? Who setts-based mobile collaborative robotics • Vuzix touched it? Did someone grab it and company, says his approach is the result • Zebra Technologies move it somewhere else? If so, is there of the lessons learned when he worked

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providers, one of the challenges the speed of conventional operations, to smart glass technology is that you now get a digital record of what it is an evolving technology. “The an associate is doing and, if you have materials handling industry can more than one facility, you can tie your be antiquated—once you get a smaller DC’s into your bigger ware- solution work, you don’t want to houses,” he says. Anderson adds that touch it,” says Anderson. “Into last year, the question from custom- that environment, we’re bring- ers was: What is the ROI? This year, ing something that is just fluid. they’re asking about the change man- We’ve been most successful agement required to roll the technology with companies whose cultures out. That’s progress. embrace that kind of disruption.” Internally, Anderson says, Vuzix has a In a sense, the niche for five-year technical roadmap that is smart glasses is developing designed around the idea of change. A along with the technology. Early multi-discipline team at the director wins have been in maintenance level and above meets regularly to because of the ability of a techni- discuss feedback coming in from the cian to remotely connect with a field along with macro-economic supervisor or engineer. Anderson changes, such as whether a large now sees possibilities in 3PLs competitor like Apple or Zebra has like DHL that have traditionally come out with something new. “We Like robotics, smart glasses such as this eschewed technology, and small ware- want to be sure we’re focused in the solution from Vuzix, is another emerging houses that can’t afford a pick-to-light sys- right direction so we’re not putting time technology showing promise in the warehouse and distribution center. tem or hardware bolted to the floor. and effort into something world doesn’t “Even if smart glasses don’t improve want,” he says.

2018 MHI Innovation Awards he 2018 MHI Innovation Awards were announced during Industry Night at Modex last T month. Launched at ProMat 2013, the MHI Innovation Awards recognize new products, product lines, technologies or services or new applications of existing products or technologies that create quantifiable and sustainable results in terms of ROI, cost savings and customer satisfaction. These awards are given in three categories: Best New Innovation, Best IT Innovation and Best Innovation of an Existing Product. The winners were:

BEST IT INNOVATION: BEST NEW PRODUCT: Yard Management Solutions for The Raymond Corp. Eagle Eye Yard Management for Raymond Virtual Software Reality Simulator

BEST INNOVATION OF AN EXISTING PRODUCT: ELOKON GmbH for ELOshield - Proximity Detection System

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opex.com/perfectpickhd | 856.727.1100 MODERN special report TOP 20 SYSTEM SUPPLIERS Across the globe, the industry achieved record-smashing growth.

BY JOSH BOND, SENIOR EDITOR

or the fi rst time in its 21 growth, making technology for the future. This spending F years, Modern’s Top 20 investment a must for many.” activity is clearly refl ected in the Systems Suppliers list Saenz adds that companies are performance of the Top 20.” shows universal revenue growth also readying their supply chains Going forward, Saenz expects among the top players, including to support a “digital transforma- the same big players will continue fi ve that grew more than 25%. tion” intended to improve the to earn the largest share of the Following annual increases of effectiveness of their logistics market, but potential acquisitions 3.5% and 6%, the list’s combined with real-time data. For many, he and mergers could further change revenues surged 16.5% in 2017. says, this transformation requires the rankings among the top Norm Saenz, managing investments in automated equip- companies. director at St. Onge Co., says ment, bar coding/scanners, RFID, “Whoever takes fi rm control momentum continues to build. warehouse control/execution sys- of delivering quality technologies “There were large increases tems (WCS/WES) and more. that enable effi cient e-commerce in investment in 2017, which “It’s so drastic that some fulfi llment and the digitization of also increased over previous companies are totally renovating supply chains will dominate the years,” Saenz says. “There’s a their existing facilities, removing 2018 rankings,” he says. “Systems focus on investing in tactical old equipment and updating such as unit sorters, mini-load systems (i.e. additional pick with state-of-the-art equipment, and shuttle systems, put walls, locations, put-walls, etc.), driven technology and software,” he pick modules and other piece-pick by massive e-commerce growth. says. “They’re trying to make a technologies will lead the way for Among retailers, wholesalers and difference by investing capital many technology companies. The manufacturers, the operational on the right tactical systems ability of these fi rms to provide tweaks made to address to address emerging market quality WCS/WES solutions e-commerce are no longer channels like e-commerce, and only increases the potential for enough to handle the continued readying their supply chains increased revenue.”

26 M AY 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com MODERN special report

Top 20 worldwide materials handling system suppliers Worldwide Worldwide Percent 2017 2016 2016 revenue 2017 revenue change Three-year Rank Rank Company Web site (million USD) (million USD) '16-'17 change Headquarters

1 1 Daifuku Co., Ltd. daifuku.com 2924 3659 25.1% 44% Osaka, Japan Schaefer Holding International Neunkirchen, 2 2 GmbH ssi-schaefer.us 2630 3060 16.3% 23% Germany

3 3 Dematic dematic.com 2016 2267 12.5% 42% Atlanta, Ga. Vanderlande Veghel, The 4 5 Industries B.V. vanderlande.com 1231 1538** 24.9% 46% Netherlands Murata Machinery, 5 4 Ltd. muratec-usa.com 1260 1287 2.1% 28% Kyoto, Japan Honeywell 6 8 Intelligrated intelligrated.com 850 1000 17.6% 59% Mason, Ohio TGW Logistics 7 12 Group GmbH tgw-group.com 568 915 61.1% 74% Wels, Austria Beumer Group beumergroup. 8 7 GmbH com 852 900 5.6% 0% Beckum, Germany

9 9 Fives Group fivesgroup.com 721 721* 0% 0% Paris, France

10 10 Swisslog AG swisslog.com 645 695 7.8% -2% Buchs, Switzerland

11 11 Knapp AG knapp.com 643 643* 0% 4% Hart bei Graz, Austria Witron Logistik + 12 14 Informatik, GmbH witron.com 453 635 40.2% 75% Parkstein, Germany Grenzebach Maschinenbau 13 13 GmbH grenzebach.com 477 477* 0% 0% Hamlar, Germany

14 15 Kardex AG kardex.com 397 425 7.1% 24% Zurich, Switzerland

15 N/A Elettric 80 elettric80.com 150 261 74.0% 99% Viano, RE, Italy Bastian Solutions, bastiansolutions. 16 16 LLC com 217 233 7.4% 39% Indianapolis, Ind.

17 17 DMW&H dmwandh.com 172 225 30.8% 80% Southgate, Mich. Stöcklin Logistik 18 N/A AG stoecklin.com N/A 153 N/A N/A Aesch, Switzerland viastore systems 19 19 Inc. us.viastore.com 140 152 8.6% 17% Stuttgart, Germany systemlogistics. 20 20 System Group com 129 129* 0% -26% Fiorano, MO, Italy

* 2017 revenues were not available by press time. ** Unaudited 12-month interim results due to the change of financial year Source: Modern Materials Handling

mmh.com MODERN MATERIALS HANDLING / M a y 2 0 1 8 27 MODERN special report

The big get bigger and achieved a three-year increase of 28%. Daifuku retains the No.1 spot this year, reporting 2017 They say a rising tide lifts all boats. In 2016, the revenues of $3.66 billion, a 25% increase from 2016 combined value of the Top 5 totaled exactly $10 that contributed to a three-year growth rate of 44%. billion, a 4.6% increase and nearly 60% of the total According to Stuart Oliphant in Daifuku’s corpo- list’s value. In that year, the remainder of the list grew rate communications department, business was good just 2%. In 2017, however, the Top 5 achieved a 17% across the globe. He says growth in revenue is partially increase for total revenues of $11.8 billion, and the linked to an increase in orders for materials handling other 15 companies shared in the good fortune and systems from the flat panel display and semiconductor collectively grew 17%. sectors in East Asia. “There is also the continuing global trend of capital Standouts and shakeups investment toward e-commerce, and newer and larger In the years since Intelligrated placed 15th on the distribution facilities,” Oliphant says. “The growth 2009 Top 20 list, it has grown by double digits in all is also underpinned by an extensive order backlog. but one year. In a 2016 transaction valued at $1.5 With continued capital investment across the Daifuku billion, Intelligrated joined Honeywell’s Sensing and Group and increased production through cooperation Productivity Solutions (S&PS) in its Automation and among its productions sites worldwide, Daifuku has Controls Solutions Business, and was rebranded as been striving to meet rapidly increased demand.” Honeywell Intelligrated. In second place, Schaefer Systems International The company gained two ranks in 2017, finishing (SSI) SSI crossed the $3 billion mark after growing in 6th place. Although final 2017 revenues were not 16%. Arnold Heuzen, president and COO, cited available by press time, Honeywell Intelligrated sup- business growth as well as the increase in the value of plied an estimate of $1 billion, up nearly 18% and con- the Euro. tributing to its 60% growth in the last three years. Following its acquisition by forklift and logistics “Continued e-commerce growth, rising consumer leader KION Group in late 2016, Dematic is now a expectations and labor trends all drive continued supply chain solutions operating unit of KION. The investment in automated systems and software,” says unit includes Dematic as well as Egemin, an automatic Pieter Krynauw, president of Honeywell Intelligrated. industrial vehicle specialist that previously placed 18th “Logistics operations are leveraging smarter automa- on this list and was acquired by KION in 2015. tion and digital transformation initiatives to become Dematic again finished third with $2.27 billion more efficient and agile. Honeywell Intelligrated is well in revenues. The 12.5% increase in 2017 follows 8% positioned to support these initiatives in the distribution growth in 2016, and adds to three-year growth of 42%. center through the power of connected solutions.” Climbing one rank to fourth, Vanderlande Finishing 2017 with $915 million, TGW’s perfor- Industries grew 25% to $1.5 billion, boosting its three- mance was good enough to jump five spots to land year gains to 46%. Shortly before the publication of in 7th place. TGW’s revenues represent 60% growth last year’s Top 20 list—when Vanderlande posted in just one year. Incredibly, this is only the second the highest growth rate on that list at 18%—Toyota largest growth rate on the list. Industries Corporation (TICO) acquired the company. In 8th place, Beumer Group again crossed the Following TICO’s 2017 acquisition of 16th-place $900 million mark following 5.6% growth. According Bastian Solutions, Vanderlande became the second to Uwe Kinski, chief financial officer for Beumer business to join TICO’s new business division called Corp., “Beumer Group experienced notable growth Toyota Advanced Logistics Solutions (TALS), which throughout the world and across its business manages North American activities in the area of segments, most notably in the airports, logistics and logistics solutions. customer support segment.” In fifth place is Murata Machinery, which in 2015 Ninth-place finisher Fives Group was unable to was one of only three companies to post more than provide 2017 revenues by press time, so the company’s 20% growth. In 2017 it grew slightly to $1.29 billion previous total of $721 million has been carried over.

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Rounding out the Top 10, Swiss- achieved 15.5% growth. In dollars, Kardex Group (including both log’s Warehouse and Distribution Witron’s 2017 revenues are up more its Remstar and Mlog divisions) Solutions division reported 2017 than 40%, and its three-year growth climbed one spot to 14th place revenues of $695 million, excluding rate is 87%. after 7.1% growth in 2017 revenues, the company’s healthcare division. Witron has added 1,000 new which caps off a three-year growth Last year’s performance follows a staff members in the past four rate of 25%. 2016 that a spokesperson says rep- years, according to a release, “We enjoyed our best year in resented “our largest order intake bringing its number of employees to Kardex Remstar USA’s history last year ever.” more than 2,800 in 2016. year, increasing our bookings by “Globally, the U.S. is our “The world becomes even more 30% over 2016,” says Mark Dun- strongest region and we enjoyed interlinked,” says Helmut Prie- away, executive vice president of record order intake, net sales and schenk, Witron CEO. “This trend is new business. “A strong economy profitability in 2017,” says Markus especially noticeable in the logistics along with continued support and Schmidt, president of Swisslog area. Information and algorithms investment from the Kardex Group WDS Americas. “We are seeing play a central role; data is undoubt- have positioned us to continue this a much more rapid adoption of edly the decisive resource of the growth in a sustainable way for the warehouse automation solutions future. However, digitization may foreseeable future.” in the market, particularly in the never be achieved for the sake of After finishing just outside the Top burgeoning e-commerce/retail digitization itself. Our projects and 20 last year, Elettric 80 has made segment.” business models must pay off at the a triumphant return to claim 15th Swisslog, which is now fully inte- end of the day.” place. After doubling within three grated into the KUKA Group world- Grenzebach was unable to years, the company’s annual revenues wide, also acquired Power Automa- report, and its 2016 revenues are totaled $261 million in 2017. tion Systems (PAS) in April 2016. enough for the company to retain “We are experiencing a huge PAS manufactures the PowerStore, 13th place. growth,” says Andrea Pongolini, a leading pallet shuttle system. Swisslog has also fully integrated both PAS and Forte Industries, which it acquired in April 2015 Making the list under the Swisslog brand. o qualify for Modern’s Top 20 list, companies must be T suppliers of materials handling systems, not just equipment Universal growth providers. In addition to manufacturing at least two major handling Knapp was unable to report rev- system components, a company must also employ full-time staff enues by press time, so its 2016 that designs, installs and integrates materials handling systems. revenues have been carried over These systems include at least two of the following: transporta- and are enough for it to retain tion devices, storage and staging equipment, picking units, sorta- 11th place. tion systems, information management systems, data capture technologies and other types of handling equipment. Witron has climbed up two ranks To be considered worldwide suppliers, companies must have to land in 12th with $635 million a presence in North America and must also be able to report in revenues. A spokesperson says materials handling revenues to Modern. (Lockheed Martin, for the company experienced strong example, is a systems supplier with a North American presence, growth on both sides of the Atlantic but isn’t included in our Top 20 list because they can’t single out and in Asia, and that the stronger the revenue that comes from materials handling contracts.) Euro also contributed to a higher dollar value. In Euro, the company

30 M a y 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com MODERN special report

vice president of sales. “We ofﬁ cer of viastore. “The global mar- year, and we expect to see another already have orders for a 2018 ketplace seemed to remain strong. year of growth in orders in 2018.” revenue of $252 million.” In addition, viastore has been grow- Last but not least at No. 20, Bastian Solutions grew 7.4% ing its business in both automated Italy-based System Group (System and held its 16-place ranking systems and our WMS software busi- Logistics, Modula) was unable to with $233 million. According to ness. All in all, 2017 was a very good report revenues by press time. Aaron Jones, president, “revenue growth came from several areas, but a few key success factors were growth in our warehouse execution and warehouse man- ® agement system implementa-

tions, increased robotic and POWER WHEN YOU NEED IT mobile robotic systems, as well as the development of composite materials and advanced control systems.” DMW&H (previously Dear- THINK born Mid-West Company, which acquired W&H Systems in late 2015) held 17th place, fi nishing INSIDE just behind Bastian with revenues of $225 million—a 31% year- over-year improvement. A spokes- THE BOX person says growth across all segments was a result of the demand in the automotive and wine and spirits distribution industries. In 18th place, Stöcklin is a newcomer to the list and reported $153 million in revenues. Tony Varda, director of business devel- With the expanded line of ® opment, says growth from non- NexSys batteries traditional automation markets, such as Russia, Brazil and Mexico Looking for a lift truck battery that lasts longer and needs less maintenance? Look no further than NexSys® batteries – have helped fuel the company’s with exclusive Thin Plate Pure Lead (TPPL) design inside recent success. the box. The expanded NexSys® battery line includes configurations that can fast-charge in just under an hour Hot on Stöcklin’s trail is 19th- and work for up to 16 hours – without a break, without ranked viastore with $152 watering and without changing. Just more time for fleet million, an increase of 8.6% uptime and a lower Total Cost of Ownership (TCO). over 2016 revenues. See how TPPL technology in every NexSys® “We attribute this increase battery can cut your TCO at www.enersys.com. to strong performance in all our markets served,” says Tom Coyne, president and chief operating © 2018 EnerSys. All rights reserved. Trademarks and logos are the property of EnerSys and its affiliates, except MHEDA, which is not the property of EnerSys. Subject to revisions without prior notice. E.&O.E.

mmh.com MODERN MATERIALS HANDLING / M AY 2 0 1 8 31 MODERN best practices

How to survive RE-LABELING

BY GARY FORGER, CONTRIBUTING EDITOR

Who wants to re-label the warehouse or distribution center? No one, most likely. But it’s got to be done, and now more frequently than ever. Here’s a best practices guide to get you through the process.

When re-labeling the warehouse, don’t overlook ﬂ oor labels such as this adhesive backed aluminum one.

32 M AY 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com MODERN best practices

et’s cut to the chase: When was the last time OK, so you didn’t go that route all those years L you considered re-labeling your warehouse ago, and your recent acquisitions haven’t exactly fit or distribution center? (There’s typically a in either. What exactly is a good Plan B? long pause about now.) In other words, you prob- Melissa Van de Motter, a sales engineer at Cam- ably can’t say when with any certainty off the top code, says the best advice is to bring re-labeling into of your head. That may not be a good thing. the process early in a DC update or reconfiguration. Just take a minute (right now would be OK) and look around your facility for a few telltale signs that it might be time to re-label. • Are your floor or rack labels or hanging signs showing wear? • Are you upgrading to a new warehouse management system (WMS)? • Has your company gone through an acquisition(s) cycle lately?

• Is e-commerce part of your mix? Hanging signs above bulk • Have the products as well as their vol- storage areas and docks may ume and velocity changed lately? need attention, too. Chances are at least one of those five are at play within your four walls. That does not necessarily mean that it is time to re-label, but it’s certainly worth a closer look if any of the five are making an impact on your ability to store, pick and ship with top efficiency. “Labeling accounts for less than 5% of total warehouse cost but is one of the most important aspects of daily operations. People don’t always realize Even standard warehouse activities can damage labels. it, but labels are a big factor in how inventory moves in and out of the facility,” says Mark “Too many people wait until it’s too late to re-label Aigner, president of Aigner Label Holder Corp. in the most efficient way,” she adds. “Being late with re-labeling doesn’t sound like a big deal until it Getting started delays startup of upgraded warehouse operations. “ That said, where do you start? The experts from Suppliers also agree that re-labeling requires a Camcode, ID Label and Aigner all agree on that thorough understanding of the facility, its environ- one: you start when the facility is being planned, ment and processes. not after it’s occupied. “Do it right the first time,” That starts with the DC layout and how it’s says Gregg Schiltz, chief operating officer of ID changing. Similarly, how might operations be chang- Label. “Re-labeling actually starts with labeling ing? How dynamic is the inventory mix beyond the warehouse in the first place,” he adds. simple velocity of specific items?

mmh.com MODERN MATERIALS HANDLING / M a y 2 0 1 8 33 MODERN best practices

There’s also the matter of equipment in the facility. bar code labels. Now, with our new WMS and mobile bar What are the types of rack? Is floor storage part of the code scanners, we’ve greatly improved our workflow pro- mix? How about bulk storage? How do the docks operate cesses. It’s helped to drive efficiencies and speed across both for receiving and shipping? You get the drift here. all our DCs and improved communication with stores.” Van de Motter adds that the data capture technology To get the needed information and manage the is just as important. What are the scanner capabilities re-labeling project requires a designated project lead from and how are they used—up close, medium-range or long the facility, says Schiltz. That person also helps the label range? All of that influences specific labeling decisions supplier to understand the business of the warehouse and (more on that later). how it operates, just as it did at Lowe’s. There’s also the matter of the WMS, which controls And it’s entirely possible that there are some internal warehouse activities. It needs the data from the labels to requirements including the style and format of the label- direct operations on the floor. Miss a beat here during re- ing. “In the end, re-labeling is very much a custom proj- labeling, and the WMS will be handicapped in its ability ect,” Schiltz adds. to move materials and products through the facility. By the way, the key points of this Plan B approach work As Schiltz explains, ID Label started in 2016 working quite well if you take Schiltz’ advice and start with label- with home improvement retailer Lowe’s on an 18-month ing the warehouse in the first place. WMS upgrade across 15 DCs handling lumber that arrives on flatbed trailers. Getting down to labels “We revamped the layout and the way we set up Now to the matter of getting the labels right. Let’s be inventory locations in each DC to accommodate bet- clear up front. There is no shortage of label options for ter processes and workflows,” says Jamie Reiss, senior the warehouse or DC. That’s good because the job at industrial engineer for Lowe’s flatbed distribution centers. hand is to re-label and fit current needs, not those that “Everything was mapped down to the inch, including our once worked.

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An early step is to review the ware- few of your options. house layout and its speciﬁ c re-labeling Let’s start with racks and shelving. Re- needs, explains Van de Motter. Possibili- labeling here is much more than scraping ties go far beyond racks and wire and off old labels and applying new ones. In steel shelving. Floor storage requires fact, the experts all agree that scraping is different labels. Meanwhile, bulk storage the worst of the worst. Not only is it highly areas and docks might need changes to labor intensive, but most people underes- their hanging signs. And, these are only a timate the amount of labor needed. The

mess of scraping is no more attractive. But the fi nal issue is how completely did that original label come off the beam? If the old is incompletely removed, the new label will never sit right and function optimally. That’s where suppliers have stepped in with several other options. These include Beam Renew from ID Label. It does not require scraping and applies directly over the old label. A different but similar style is larger than the old labels and can be applied directly over them, ensuring strong adhesion to the rack beam. Yet another, which goes back to the fi rst- time advice earlier, is a quick-release label from ID Label. Known as Clean Release, this family of labels is a removable, reposition- able label. An advanced adhesive allows for easy installation and removal of the labels, eliminating the traditional removal process for re-labeling. The technology was a fi nalist in MHI’s Innovation Awards at last month’s Modex 2018 show. Aigner takes a completely different approach. Rather than labels, it offers label holders. As Mark Aigner explains, holders completely eliminate the need to scrape labels from racks and other locations. Instead, the holder stays in place while the label in it is switched out, saving costs and labor. Once in place, label holders protect bar code and other types of labels from dust and dirt for accurate scans. Holders can be affi xed permanently with one type of adhesive or made movable with a reusable adhesive. There’s also the option to eliminate adhe- sives altogether—magnetic labels. Depend-

36 M AY 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com MODERN best practices ing on the supplier, magnetic labels can be might have been even a few years ago. The hand-printed or computer-printed, depend- simple dynamics of inventory and velocity Companies mentioned ing on needs. They are easily applied to a make re-labeling a more frequent consider- in this article metal surface and moved to a new location ation to ensure maximum facility effi ciency. when re-labeling occurs. In fact, Lennox Fortunately, there are more options than • Aigner Label Holder Corp. uses 5,000 customized magnetic rack labels ever to help you keep pace. In the end, the • Camcode in its warehouse in Georgia. biggest challenge might well be overcoming • ID Label Moving onto fl oor storage, at the Modex inertia in the fi rst place. show Camcode featured a highly durable

adhesive fl oor kit. A picture or other data | can be photographically imaged on the PC11-47USA aluminum label with an adhesive backing. | Other styles include a screw-down aluminum frame for fl oor labels. “Low cost” doesn’t have In bulk storage and dock areas, hanging signs are often the best way to go. Cam- to mean “low quality”. code’s retro-refl ective signs hang from a chain or wire and scanned from distances up to 50 feet. The Lennox DC mentioned earlier uses 1,300 of ID Label’s retro-refl ective signs in bulk storage.

Pulling it all together So, re-labeling the warehouse is part of the DC upgrade plan. Fortunately, you don’t have to go it alone through the evaluate, specify, print and install cycle. Label suppliers typically offer services to evaluate the DC, determine its needs and make recommendations for re-labeling options. In most cases, the entire process takes less than a month. However, larger www.beckhoff.us/ipc-entry-level facilities may require more time. The CP6706 Panel PC combines: Label distributors also fi gure in the pic- high quality construction – aluminum front, sheet steel rear cover ture. For instance, that was the route Len- a full color 7-inch TFT touch screen display (800 x 480 WVGA) nox took with its Georgia DC. Intel® Atom™ (up to 4 cores) and 2 to 8 GB DDR3L RAM Cold storage, especially freezer environ- ultra-compact CFast memory card for the storage media ments, are a high-profi le example where outside expertise is especially valuable. Standard labels are not likely to be the best option. Not only is it a matter of appropriate Also available, label selection but adhesive, too. Testing of CP6606: several options is a standard course before 1 GHz ARM Cortex™ making a fi nal decision. And just as impor- A8 CPU, and 1 GB DDR3 RAM tant is the impact of the environment on the installation of the labels. Clearly, special expertise is best. In the end, re-labeling a warehouse or DC today is a different proposition than it

mmh.com MODERN MATERIALS HANDLING / MAY 2018 37 BY GARY FORGER, CONTRIBUTING EDITOR

alk with enterprise resource planning (ERP) suppliers about their warehouse management systems (WMS) long enough, and it feels like a proxy about the future of next-generation supply chain technologies. Artificial intelligence (AI), Twearables, voice, data analytics, Internet of Things (IoT), and, of course, the Cloud all figure prominently in the discussions. Many in the supply chain look at several of those technologies as barely here in 2018. But clearly, so much development emphasis on next-generation technologies in ERP WMS does bring a new vibe to the discussion. “We now know that these advanced technologies are no longer futuristic concepts— they are a reality,” says Diego Pantoja-Navajas, vice president of WMS development for Fusion SCM development at Oracle. It’s imperative to note that all of this is in the early stages of building even more highly integrated, connected ERP WMS systems. But there does seem to be a sense that what

38 M a y 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com MODERN information management

THE PATH FORWARD FOR ERP WMS

There’s nothing static about warehouse management systems from enterprise resource planning suppliers. The user base is expanding at a notable clip, and next-generation supply chain technologies from the Cloud to data analytics and smart glasses are in their future.

has long been called “good enough” WMS is moving in a direction that brings even more value to distribution operations. However, the question remains: Is ERP WMS at an inﬂ ection point for shedding the “good enough” moniker for its software? The answer to that is somewhere in the future, but there’s no question ERP WMS is in as strong a position as it has ever been.

Where ERP WMS sits today ERP Dwight Klappich, vice president of supply chain execution research at Gart- WMS ner, says a recent study of his indicates ERP WMS is growing faster than best-of-breed WMS in terms of new clients. This is the ﬁ rst time in the 11 years of Gartner’s supply chain technology user study that has been the case, he adds. Beyond new clients, mega-suite suppliers (Klappich’s name for ERP WMS suppliers) are strongly favored among users. Klappich says 62% of study respondents are strongly

mmh.com MODERN MATERIALS HANDLING / M AY 2 0 1 8 39 MODERN information management

committed to a single mega-suite provider such as Infor, Going forward, both WMS armies face a changing dis- Microsoft, Oracle or SAP. And, 47% of respondents say tribution world. To begin, several distribution segments are they have a strong preference for their mega-suite pro- undergoing unprecedented change. Key areas are retail, espe- vider’s WMS and will only look elsewhere if the offering is cially omni-channel retailers, consumer goods companies and notably substandard. industrial distributors, says Gilmore. He goes on to say that among the half dozen most On a broad scale, the types of DCs are changing, too. prominent supply chain modules in the mega-suites, Companies continue to build large, automated DCs with high WMS is “extensively utilized” by 38%. Only the order volumes requiring complex order fulfillment functionality—long management module is more favored at 40%. the stronghold of best-of-breed systems. At the same time, What’s the state of ERP WMS today? “It’s healthy, there’s a move to putting DCs closer to customers, resulting in mature, a workhorse and tightly integrated with ERP and its smaller DCs—the traditional sweet spot for ERP WMS. business apps that impact the warehouse and vice versa,” But across the board, the battle going forward will be the according to Justin Ward, senior product manager at Epicor. same: How do warehouse management systems receive, fill That doesn’t mean ERP-provided WMS is in a and ship orders with the fewest constraints along the way? dominating position. It isn’t. This is the story of how ERP WMS is approaching that goal. Best-of-breed WMS is in a strong position, too, says Dan Gilmore, chief marketing officer for Softeon. “The Value of the Cloud idea that ERP WMS is going to put best-of-breed out of Next-generation technologies clearly have great business is not even part of the discussion today. There’s promise for ERP WMS packages. Regardless of enough market for all suppliers of WMS,” he says. the technology in play, the intent is to build even

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greater real-time inventory visibility than is possible today. At this point, it is not unheard of to run ERP WMS Suppliers consistently tout the integration of their in the Cloud. But it’s worth noting that many different WMS modules with other segments of the ERP system. forms of the Cloud are available. Many call it embedded and point out that there’s no need For instance, IFS senior advisor Jakob Bjorklund to synchronize the two. But, the story doesn’t stop there. speaks of his company’s software-as-a-service (SaaS) Best-of-breed WMS is best known for its superior that runs the WMS completely in the Cloud, completely functionality. That is where ERP WMS wants to go and managed by IFS. There’s also IFS Managed Cloud that where next-generation technologies show their mettle. runs in either a highly secure, private installation that is Most of them start with the Cloud. While the Cloud is fully maintained, updated and monitored by IFS. not new to ERP WMS, it’s taking on added importance. “To Meanwhile, Oracle speaks of its SaaS as well as its begin, hundreds of installations have made it clear that you platform-as-a-service (PaaS) and infrastructure-as-a-ser- can run WMS in the Cloud,” says Pantoja-Navajas. “Fur- vice (IaaS). The platform approach offers three different thermore, real Cloud applications are laying the foundation schemes for the user and Oracle to manage and control for innovative solutions from IoT to blockchain.” the ERP system with different degrees of Cloud privacy. “Companies that want to go into the Cloud want to eliminate customization as well as the impact of integration Data analytics move in without sacricing functionality,” says Infor’s industry strate- When it comes to next-generation technolo- gist Edward Talerico. “Information technology should be a gies, the Cloud typically supplies the back- commodity. That allows companies to focus on making and bone to integrate the visibility supplied by selling widgets. The Cloud allows them to do that,” he adds. them. Data analytics offer a new way to look at all that data

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so visibility results in the right actions at the right time. the movement of inventory through Infor calls it connected intelligence. About a year ago, the company the supply chain,” he says. purchased Birst for its Cloud-native, business intelligence analytics and Earlier this year, Epicor introduced data visualization. As Talerico explains, it’s a matter of managing data Epicor Data Analytics (EDA) for through predictive analytics to improve the flow of product from manu- Prophet 21 in the Cloud. While EDA facturing through to the customer. “If a company can anticipate demand has a broad portfolio, Epicor’s Ward through predictive analytics, it will require less inventory and can speed says the package’s capabilities can get as granular as analyzing demand, inventory and warehouse location to streamline flow through the DC. He continues to say, “there is a huge We take great pride in opportunity for data analytics in ERP WMS. It can improve workload, work- delivering great power. flow, inventory levels and staffing. It can go so far as to manage picking tasks based on the work queue, track the time needed to pick items, and predict how long it will Douglas Battery™ delivers reliable power, customer take to pick an order. It’s a matter of com- support and innovative prehensive integration of data to improve battery and charger solutions operations.” to keep industrial equipment Ward has other aspirations for data moving with maximum power and minimum analytics, too. He expects that, in time, downtime. We provide it can be used to reduce warehouse motive power solutions to labor costs as much as 10% to 20% customers around the world through improved productivity out on with trusted battery and charger solutions for material the floor. handling and airport ground support equipment – from On the warehouse forklifts to walkies and more. ﬂoor Fortunately, data analytics is just one of the technologies moving ERP WMS forward. Voice, augmented reality smart glasses and autonomous mobile robots are part of the mix at the pick face, explains Richard Kirker, SAP’s global solutions owner for WMS. At an SAP warehouse in Germany, autonomous mobile robots from Fetch Robotics pick multiple orders in mul- Douglas Battery tiple picking areas. 2366 Bernville Road • Reading, PA 19605 “The robots are smarter than tra- 1-800-DOUGLAS • www.douglasbattery.com ditional AGVs, which operate much like a fixed conveyor,” says Kirker. As a result, he explains, the robots need ©2018 EnerSys Delaware Inc. d/b/a Douglas Battery. All rights reserved. Trademarks and logos are the property of EnerSys and its affiliates unless otherwise noted. fewer messages than conveyors from Subject to revisions without prior notice. E.&O.E. the WMS to pick items and orders

42 M a y 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com MODERN information management

Getting there requires a four-pronged approach, says Infor’s Talerico. Companies mentioned First, improve the user experience through better warehouse workfl ow. in this article Second, increase functionality based on specifi c industry requirements. Third, maximize the impact of the Cloud’s capabilities. And, fi nally, build • Epicor • Oracle emerging technologies into the mix to add functionality to ERP WMS. • Gartner • SAP By all indications, this is more than aspirational. The path forward for • IFS • Softeon ERP WMS is set for now. • Infor across the warehouse fl oor. In other TAILORED SOLUTIONS words, the ERP WMS running in the For any production environment Cloud leverages the robots’ autonomous capabilities to effi ciently pick items and deliver orders to shipping. A completely different approach to picking involves smart glasses, says Kirker. FROM SOFTWARE And, he’s quick to point out these are fairly high-tech picking glasses for hands- TO STORAGE & RETRIEVAL free data management. At a high level, the WMS directs picking and communicates with the picker through voice commands and augmented reality on the smart glasses. A camera integrated with the glasses scans bar codes. That combination, says Kirker, delivers commands directly to the picker and confi rms accuracy of picks long before the assembled order gets to shipping. Under SAP’s approach to Cloud- deployed WMS, the Cloud ensures rapid communication with the smart glasses. Without the Cloud, the lag time to relay all that data and messaging from the WMS would slow the picker to unac- ceptable levels. TO SORTATION & TRANSPORT The long game Clearly, ERP WMS is mov- TRUST MURATEC. ing into new territory. All of what is discussed in this article ranges from available today to early pilot stages. But, there is a path. muratec-usa.com | 704.875.9280 “We’re pursuing real-time inventory visibility at all stages supported by a WMS that is part and parcel of ERP. The idea is to streamline where possible and deliver higher functionality,” says IFS’ Bjorklund.

mmh.com MODERN MATERIALS HANDLING / M AY 2 0 1 8 43 WAREHOUSE BASICS: AUTOMATED STORAGE SYSTEMS EMBRACE NEW ROLES Distribution and fulfillment applications are looking to automated storage to do what it does best—plus a little bit more.

EQUIPMENT PART 2 AUTOMATED STORAGE

MODERN equipment report

BY JOSH BOND, SENIOR EDITOR

t this point, it’s clear that you have a good pick rate? An accurate For newcomers, the process of marry- automation will continue pick rate? Labor strain or injury issues? ing the right AS/RS to business objectives to permeate materials han- Automation tends to grow organically doesn’t require mountains of data, but it’s dlingA as warehousing and distribution from those starting points.” not a molehill either. operations reshape themselves to meet “The ultimate goal is to get the right unprecedented demands. Familiar and To pallet, case and each their own item to the customer in the right quan- previously specialized technologies have Every company will approach automation tity, so if you are strategic with that goal been adapted to suit a broader range of differently and, perhaps not surprisingly, and work backward, the technology applications, bringing the capabilities of it is the smaller organizations that stand selection starts to become obvious,” says large and expensive Bill Grey, executive sales automated systems manager of the automated Shuttles and mini-load AS/RS systems are experiencing growth in to smaller operations. light of increased interest in goods-to-person methodologies. systems division for SSI As inventory engines, Schaefer Systems Interna- automated storage tional. “That said, it’s not and retrieval systems as easy as it sounds. A lot (AS/RS) are among of people struggle when the most potentially they don’t know the num- transformative sys- bers. How many orders do tems. They stand at we ship? How fast? Can the center of many we spread the workload goods-to-person meth- across the day instead of odologies buffering scrambling before the ship- and sequencing strate- ping window closes?” gies and the overarch- First, Grey says it’s ing need for accuracy, important to define load density and speed. units, whether pallets, lay- High school, ers, cases or eaches. Will technical school and the AS/RS feed a produc- college graduates will tion line in manufacturing, play an important role or is it in a DC that brings in shaping what comes in full pallets and repack- next. In the meantime, ages them as mixed case the expert insights in this article are a to benefit the most from currently pallets? Are you looking to simply store small sampling of the available solutions. According to Rick goods, or store before turning them into wealth of opportunities in this space. Graff, product manager for Honeywell something else? “A high school grad needs to walk Intelligrated, an operation with manual Next is determining the rate at which into this with eyes wide open,” says picking from ground-level storage can you need to store and retrieve. Grey esti- Tim Archer, training manager in the easily justify automation. mates automation might not be ideal at Americas for Kardex Remstar. “They’re “On the other hand, a big box DC less than 50 pallets per hour in and out. going to see a wide variety of storage where they’re trying to eke out a percent Assuming a system will handle single- methods, everything from cabinets to or two of performance over a two-year old SKU pallets, how many SKUs? Do SKUs standard rack, to shelving, to flow rack. system, they’re leaning into the wind,” have expiration dates? Must they remain Businesses from small to large are not Graff says. “Or, they’re using the Internet in first-in, first-out (FIFO) sequence? always ready to jump into automation. of Things to collect mountains of data and Do you need high selectivity, meaning Newcomers to this business should look categorize it in a way that makes sense to storage is configured to enable access to at where they are in the process. Do find areas of improvement.” individual pallets? Or, do you store a lot mmh.com MODERN MATERIALS HANDLING / M a y 2 0 1 8 45 MODERN equipment report

of the same thing and rotation isn’t as Cranes are characterized by a single for pallet AS/RS since it’s still the most critical, in which case you can achieve load handling mechanism per aisle. efficient way to move goods,” he says. greater density? Cranes that handle pallets (unit loads) “Even though the growth in e-com- Then you must consider the physical might be able to handle one, two or mul- merce means more SKUs are eventually constraints of the new or existing facility. tiple pallets at a time, typically at a limit broken down into eaches, the initial of about 3,300 pounds. unit is still a pallet.” Cranes can also be As automated storage supports designed to handle totes, ever-smaller orders and storage trays and/or cartons (mini- quantities, Graff predicts another load), which are limited wave of shuttle technology. to about 75 pounds. Both “There are already some shuttles unit load and mini-load that have become even smaller in size, systems can access any handling pharmaceutical or other small storage location in the items,” he says. “I expect those solutions aisle and present goods will trickle into the distribution and at one or both ends of order fulfillment space, where they can the aisle. Grey offers a now downsize one more time to half the conservative estimate space and twice the SKUs. If that trend that cranes can execute takes hold, we might see another step in 25 double cycles (store/ shuttle evolution.” retrieve) per hour. Applications with low Software and solutions SKU counts are more In terms of both equipment design and likely to store product mul- software, the evolution of AS/RS solu- tiple-deep in a given locations has rapidly accelerated in recent tion, or lane. This boosts years, Graff says. density, but places limits “Technology is advancing faster than it on throughput; it’s quicker ever has in materials handling, and espe- to access a five-deep lane cially in storage and retrieval,” he says. than one 25-deep. “The big driver we see now is software For, say, 20,000 pallets creativity, and the more creative the soft- of only 200 SKUs, Grey ware folks get the more creative the hard- says shuttles are a good ware folks have to get. Everyone is trying supplement to such a sys- to get faster and more accurate deliveries, tem. Instead of a fork-type all of that trickles through to equipment, telescoping load handling and it’s all disruptive and causes chaos. unit, the crane can be fit- You think you’re building for the future, ted with a bed or chassis but by the time you get a system designed for a shuttle. The shuttle to achieve two-day shipping, someone Automated storage can boost density, in part by making can then leave the con- says you now need one-day.” the best use of vertical space. fines of the crane to travel The pressure for speed and precision down a lane. means software has to efficiently coordi- If new, it might make sense to build a very Grey says it is increasingly common for nate resources from equipment to labor tall AS/RS crane to maximize the use of facilities to use both unit load and mini- to storage space. Software providers are vertical space. Grey says cranes can reach load systems. now focused on timing, Graff says. If an heights of 130 feet standard, and as much “We are seeing more combination order should be sitting at the shipping as 150 feet in some conditions. systems, but there is still a large need door at 2:56 for a truck leaving at 3:07,

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MODERN equipment report

the software must work backwards from holistic view upstream and downstream “The goods-to-person (G2P) trend that point to determine the optimal time of the AS/RS. has really created a need for an inven- to launch the order. If it gets to the dock “The software piece wants known tory storage engine that can feed these too early, it’s in the way. If too late, it entities coming in, and to produce G2P stations accurately and at the misses the truck. known entities,” Graff says. “The trick is right time, volume and speed needed “You want to shrink the amount no issues, no problems and everything of time an order needs by requiring on time. Obviously nothing will ever be fewer steps or less distance, which also 100%, so you must decide how you han- reduces the potential for problems along dle exceptions in a manner that doesn’t Core business the way,” Graff explains. “If you’re trying disrupt any other processes.” case for AS/RS: to push more through a building, the The three Cs fi rst thing to cut is anybody’s buffer. The AS/RS in new roles guy at the dock used to have a buffer In this dynamic business climate, excep- ontrol inventory: Strategic location pallet for anything that came early. To tions are increasingly becoming the rule. C management, tracking, take that real estate back, the software In addition to the conventional storage LIFO (last-in, first-out), has to be that much smarter.” role for AS/RS, there’s a growing range of FIFO (first-in, first-out), An AS/RS supporting shipping can applications that leverage AS/RS func- FEFO (first-expired, first- provide case buffer capabilities and tionality to address contemporary chal- out) rotation, speed, con- bring out cases and orders in a specifi c lenges. Ken Ruehrdanz, manager of the trolled access, accuracy, sequence to build a rainbow pallet or distribution systems market for Dematic track and trace, cold chain fl oor load trailers in route-stop sequence. North America, says the business case and temperature control. But again, the software must have a for automation is changing. ompact footprint: CHigh density, less space, accommodate more SKUs, energy savings, reduced building and land costs.

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– Maximum density Growing applications – Extremely flexible for AS/RS include: 1. goods-to-person engine, 2. order consolidation, 3. automatic pick face replenishment, and 4. feed palletizing. DAMBACH Lagersysteme Inc. 5295 West River Drive, Suite 200, Comstock Park, MI 49321 Office: +1-616-784-6484 [email protected] www.dambach-lagersysteme.com

48 M AY 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com MODERN equipment report

to keep those stations busy,” Rueh- rdanz says. “The largest and most signifi cant trend is using AS/RS as Companies mentioned in this article an engine to fulfi ll.” • Dematic • Kardex Remstar Ruehrdanz says order consolida- • Honeywell Intelligrated • SSI Schaefer Systems International tion is another growing application. As orders are built in boxes or totes or what have you, an AS/RS is ideal for both consolidation and buffering before sequenced release to outbound trucks. “This is a new trend, but it’s EXPERIENCED being embraced and accepted, especially in food and beverage and e-commerce,” he says. “Previously, GUIDE. you’d have accumulation conveyor or just manually stacked goods at the shipping dock, which is messy and labor-intensive.” The practice of using an AS/ RS to automatically replenish pick faces is also on the rise, Ruehrdanz says. For both pallets and cases, manually traveling to reserve storage and replenishing forward pick faces consumes time, space and labor, whether or not there are separate, dedicated aisles for picking and replenishment. Integrating WITH OVER 12,000 UNITS INSTALLED AND automation with traditional manual 13 UNIQUE DIMENSIONING PRODUCTS, picking often proves an effective, EXPERIENCE IS OUR GUIDE. accurate solution. “You can see why AS/RS started as basically a storage machine,” In 1987, we had an idea. Over the past 30 years, that Ruehrdanz says. “These new uses idea has grown into an industry. We have seen many like consolidation, G2P and auto- dimensioning companies come and go over the years, but we have remained. We listen to our customers, learn mated replenishment are not new, by working in their environments and innovate as their but they are breakout applications needs change. Our software, technology and staff are all in terms of growth and implementa- developed to make our customers more efficient and tions, especially since they’re all more profitable. When we work with our clients, our retrofi ttable into existing facilities. experience is our guide. Give us a call today to learn It’s not a matter of being driven just more. by a need for dense storage, for example. The trend is that automated storage is expanding and 800.488.CUBE fi nding new applications because [email protected] there are new roles.”

mmh.com MODERN MATERIALS HANDLING / M AY 2 0 1 8 49 Modex 2018 SHOW WRAP UP

Modex 2018, April 9-12, covered more than 300,000 net square feet of exhibit space on two show ﬂ oors at Atlanta’s Georgia World Congress Center with 900 exhibiting companies. The expo was co-located with the Georgia Logistics Summit. Here’s a look at some of the booths Modern’s editors visited.

Kardex Remstar launched remote support service Kardex Remstar launched a Cloud- Chelsea Tarr, marketing communications based Remote Support platform that coordinator, demonstrates Kardex Remstar’s continuously monitors the status Shuttle XP 500, which features new Access Ready light technology. of installed systems and remotely maintains them as needed. displayed. “The LR 35 is ideal for single-part “There are two key features included or small-volume orders,” continued Dunaway, in the new support platform,” said who noted the unit includes a shelf system Mark Dunaway, EVP of new business. with automatic bin handling, picking stations “Remote Assistance manages diagnostics and logistics software. “It delivers totes of and allows simple maintenance requests small items to operators with minimal wait to be performed remotely instead of on site to cut time, speeding up order picking and reducing the amount of downtime; and Remote Analytics, which gives users access fl oor space required to store items.” to machine data anywhere with the Internet.” Also new, Access Ready light technology can now be Additionally, the new LR 35 vertical buffer module added to the Shuttle XP VLM, alerting operators to the (VBM) and the Shuttle XP vertical lift module (VLM) are tray’s arrival in the access opening. Dematic demonstrated versatility of new modular Scott Watts, EVP for Dematic North America, GTP solution shows the company’s Multishuttle with inter- Dematic introduced a modular, turnkey goods-to-person aisle transfer capability. (GTP) solution to provide a fast and scalable order fulfi llment engine. The solution combines the secure, high-density inventory management benefi ts of Dematic’s Multishuttle with VP of global solution management. “Its dynamic, compact the compact, high-speed advantages of patented inter- design manages inventory accurately and delivers items to aisle transfer capability. It includes a high-density buffer- pickers quickly. This allows our customers to extend order ing and sequencing engine with multi-purpose ergonomic cutoff times, speed up shipping and delivery windows, and workstations used for picking, packing, replenishment, even enables them to expand into new service areas.” robotic cells or all of the above. Khodl said ROI is typically less than three years. The “Industries with high SKU volumes will especially ben- modular design lowers initial cost, he said, and the solu- efi t from our enhanced GTP solution,” said Mike Khodl, tion’s scalability improves fl exibility.

50 M AY 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com Honeywell Intelligrated’s Momentum WES connects orders, automation and labor Honeywell Intelligrated offered a live demonstration of Distribution Center,” said Momentum, its new software platform for distribution Pieter Krynauw, president centers that streamlines and simplifi es complex of Honeywell Intelligrated. e-commerce fulfi llment operations. Krynauw also emphasized The warehouse execution system (WES) brings to- improvements to the com- gether automated equipment, workfl ows, orders and labor pany’s Lifecycle Support Pieter Krynauw, president in a unifi ed platform. The system provides e-commerce Services. Hardware-agnos- of Honeywell Intelligrated, fulfi llment, store replenishment and wholesale distribu- tic cybersecurity and data demonstrates Momentum’s real-time metrics with a tion center operations with shortened order cycle times, collection have enabled a live feed from a facility improved order accuracy and faster deliveries. new approach to service. demonstration center. “Many of today’s warehouse execution systems are a “You can’t have an army patchwork of custom software and control solutions, so of people maintaining and fi xing such complex systems,” we’ve taken a vastly different, clean-sheet approach that Krynauw said. “You need systems that are smart enough prioritizes stability and simplicity to enable a Connected to heal themselves.”

New reach truck, VR training simulator at Raymond Showcasing the interconnectivity between the digital and DCs can obtain real-time information—from opera- and physical worlds, The Raymond Corp. highlighted its tor performance to certifi cation tracking to operational Reach-Fork truck series. effi ciencies—helping achieve maximum productivity and The vehicles are now visibility,” said Michael Field, CEO. integrated with tech- Introduced at Modex, Raymond’s new high-capacity nologies and scalable Reach-Fork trucks reach an industry-leading 542 inches telematics to enhance and lift up to 4,500 pounds for increased productivity the operator experience and storage utilization. and increase productiv- Also displayed, the Raymond Virtual Reality Simulator A Raymond representative guides an attendee through a virtual ity. has been updated to offer reach truck instructional reality training program that uses “With integrated modules, providing advanced, hands-on instruction to a standard reach truck. trucks, warehouses improve operator profi ciency and build confi dence.

SSI Schaefer debuted shuttle, highlighted VLM and WMS SSI Schaefer expanded its shuttle portfolio for small load Mark Dickinson, SSI Schaefer’s head of IT sales in North America, carriers with the new SSI Flexi Shuttle. The modular single- with the new Flexi shuttle. level shuttle system handles a wide variety of stored goods with a storage capacity of up to 110 pounds. shuttle also works in deep freezers. The unique feature of this system is the adaptability “In comparison to conventional ap- for storage location sizes. This feature works by having plications, the SSI Flexi Shuttle does fl exible positioning within the racking system, which ef- not rely on fi xed-allocation storage fi ciently stores a broad spectrum of load unit dimensions, positions within the racking system,” up to 860 x 680 mm (33.85 x 26.77 inches). The design said Peter Berlik, technical CEO. “Paired with intelligent allows installation at any position throughout the storage IT strategies, the rack design allows size-independent, fully aisles and combines automated storage, buffering and automatic, space-optimized storage, and therefore offers sequencing. Moving at speeds up to 4 m/s (13 ft/s), the operators previously unheard of possibilities.” mmh.com MODERN MATERIALS HANDLING / M AY 2 0 1 8 51 Zebra displayed latest mobile technology A leader in rugged mobile computers, investments. Available in multiple form factors, bar code scanners and bar code printers the device provides powerful and easy-to-use enhanced with software and services advanced data capture features that can scan to enable real-time enterprise visibility, 1D/2D bar codes in any condition. Zebra Technologies demonstrated its latest Zebra also displayed the LI3608-ER/ innovations. LI3678-ER 1D Ultra-Rugged Scanner. Mark Wheeler, The MC3300 handheld computer series Designed to capture virtually any 1D bar director of supply is an Android-based computer fortifi ed with code from as close as 2 in./5.1 cm to as far chain solutions, with Mobility DNA to help simplify the deploy- as 56 ft./17.1 m away, this versatile device the MC3300 mobile ment and application development required to allows workers to capture codes in hand as computer. transition from legacy Windows-based mobile well as on the top of warehouse racks.

Rite-Hite debuted two new products Rite-Hite showcased two new products HVLS fans—which will be available for sale at the show. The Direct Drive HVLS Fan in early-July—with a single control box. and the Trailer Stabilizer round out the Rite-Hite’s new Trailer Stabilizer rolls manufacturer’s product line. into place and can be raised and lowered The HVLS fan comes in ﬁ ve sizes (8 feet with a crank. Featuring two support legs, to 24 feet) and is powered by a direct drive this stable, mobile product is rated for that requires no oil—a feature that makes 80 tons. Rite-Hite also demonstrated Walt Swietlik, director of it attractive for “clean” warehouse and DC the Dok-Commander System and a new customer relations and sales environments, such as food or pharmaceu- graphic user interface (GUI) control panel support for Rite-Hite, with ticals. Users can control up to 24 of the at its booth. the Trailer Stabilizer.

Knapp introduced new shuttle technology, operational optimization software A new shuttle AS/RS—the OSR Heimo Robosch, executive VP of Knapp, Shuttle Evo—debuted in a press explained the benefits of the OSR Shuttle Evo as Kevin Reader, Knapp’s conference led by Kevin Reader, director of marketing and business director of marketing and busi- development (right), looked on. ness development at Knapp. Completely redesigned, the workstations for e-commerce, automated shuttle packs more functions case handling and palletizing, or quality and greater energy effi ciency control, Reader said. “It also now travels into a smaller size, enabling it as high as 130 feet and distances of 650 to travel faster, increase system feet, a 25% improvement over the previ- density and reduce a facility’s ous models.” carbon footprint. Knapp also showcased its new red- Ideal for either Greenfi eld or existing buildings, “the PILOT software that serves as a control panel for senior shuttle structure now integrates the lifts and conveyor managers seeking to leverage Big Data, predictive modeling, queuing, dramatically increasing its fl exibility and adapt- analytics, Internet of Things (IoT) and artifi cial intelligence ability by making it a much simpler process to add on (AI) to optimize warehouse and DC operations.

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You have a lot to do. Why would you worry about printing and placing all of your Beumer rolled out new sortation solution Beumer Group introduced a new, high- speeds of up to 590 feet/minute, the BG performance sorter solution. Available Sorter is powered by an OptiDrive, or linear in cross-belt and tilt-tray designs, the synchronous motor (LSM), and a contactless BG Sorter features real-time wireless energy supply. communications and ensures the highest The sortation solution was released quality of sortation and safe handling of to the North American market for the items. ﬁ rst time and is designed to provide Combined, these features allow almost all optimum support for warehouses and items to be handled through the automated distribution hubs operating in the Terry Brown, director of sales, system resulting in higher efﬁ ciency and demanding e-commerce and Industry 4.0 with the new BG Sorter. later cut-off times for customers. With sorter environments.

Markus Schmidt, president Swisslog showcased robotic, data-driven of Swisslog Logistics Automation for the and fl exible automated solutions Americas Region. Swisslog Logistics Automation demonstrated a variety of tions using Alexa and SynQ. scalable, future-ready solutions designed to give custom- Markus Schmidt, ers the fl exibility to meet changing demands. Part of the president of Swisslog fi rm’s strategic initiative to help companies keep pace Logistics Automation for with Industry 4.0, these solutions include the new Car- the Americas Region, dis- ryPick KMP600 AGV, the ItemPiQ picking system, and cussed Swisslog’s perfor- Swisslog’s SynQ software platform. mance over the last year, Booth visitors were able to interact with virtual and several of the firm’s active augmented reality applications for an up-close-and-personal projects (including retailer look at the added value that virtual warehouse planning and Von Maur), and hinted that the solutions provider could pick-by-vision picking deliver. In addition, Swisslog demon- “double in size over the next three to four years if cur- strated how speech recognition enables warehouse opera- rent market conditions continue.”

Vargo and Kindred partner for robotic put walls Last year, Vargo went live with three sunglasses and jeans, and was quickly major e-commerce facilities for retailers able to pick 385 to 558 units an hour. and wholesalers, including a robotic put Art Eldred, client executive of systems wall system for The Gap. engineering for Vargo, said the company’s Powered by Vargo’s continuous experience with WES is helping it ex- order fulfi llment engine (COFE) and pand its integration of robotics. warehouse execution system (WES), “We’re trying to simplify the WES as well as machine learning AI from space. We know what a WES is good robotics startup Kindred, the system at and what a warehouse management Vargo’s system consists of a consists of a fi xed robot at the center of system (WMS) can do,” Eldred said. fi xed robot at the center of a a circular put wall. The claw-type robot “If there are no lines of demarcation, circular put wall. learns how to pick items, recognizing they encroach on each other and it can the different handling requirements for become messy quick.”

54 M AY 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com Host of services, technologies showcased at Tompkins Jim Tompkins, CEO of Tompkins very large online retailers,” he said. International, said that in spite of “As we got into MonarchFx, we explored a variety of his entrepreneurial ventures into technologies that would enable effi cient and effective distribution and technology busi- each picking. We found the answer in China, and have nesses, his supply chain consult- unveiled Tompkins Robotics, a unique sortation system ing, implementation and integra- that allows us to sort a batch pick into a unit pick, tion is still going strong—and is pack it out, and then use the same robots for shipping busier than ever. sortation,” said Tompkins. “Under Tompkins International, Finally, to optimize warehouse asset utilization, the Jim Tompkins, we’ve added three interconnected Connected Warehouse Internet of Things (IoT) platform founder and CEO of Tompkins International, companies with different purpos- connects labor, automation and facility functions, col- discusses “the es,” Tompkins explained. The fi rst, lects data on all operations, and sends it with a gateway connected warehouse.” MonarchFx, is an alliance with to a Cloud-based analytics system. The system looks 3PLs, transportation and technol- at current productivity and offers real-time options for ogy providers. The group has created a distributed logistics modifi cations that improve performance. network of fulfi llment centers to support retailers and “Both the Tompkins Robotics and Connected Warehouse brands shipping direct-to-consumer. “It gives these opera- systems are available for implementation into operations tions a way to deliver as quickly and as inexpensively as the outside the MonarchFx alliance,” Tompkins added.

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New ring scanner from Honeywell SPS incorporates mobile computing capabilities in a single device Honeywell SPS highlighted its recently In Honeywell SPS’s cut-resistant glove released 8680i Wearable Mini-Mobile, a version, the 8680i is activated by compact hands-free cordless device that conductive fibers embedded in the thumb and fingertip. combines the form factor of a ring scanner with integrated computing and connectivity. ers’ scanning times by approximately 5 Designed to improve efﬁ ciency and seconds per typical transaction. productivity for scan-intensive tasks, the Honeywell also showcased Connected device offers 8-hour and 10-hour bat- Freight, a shipment monitoring solution tery options and ring scanner or glove- that delivers real-time data at the trailer, mounted versions. The lightweight, pallet or even package level. Equipped Wi-Fi-enabled device provides workers with a two-button with seven sensors, disposable tags relay information to a interface and a display of information such as battery Gateway device or standard cellular device to transmit data status and scan results. By eliminating the need to hold a from anywhere in the world to a portal accessible by any sup- separate mobile computer, the 8680i can improve work- ply chain stakeholder.

Hyster prepares to electrify Big Truck ﬂ eets To further its focus on environmental while also reducing their carbon footprints. sustainability, Hyster Company announced that With such previous successes, the company it’s now testing its high capacity lift trucks— will now use electric trucks to achieve two including the H170-190FT series—with electric primary goals: zero emissions and high motors powered by lithium-ion. proﬁ tability. The announcement comes after the “In particular, these goals will be ac- company’s successful implementation complished through the implementation of of low-emission Tier 4/Stage IV diesel electric power solutions,” said Steven LaFe- Hyster’s H170-190 FT engines in its Big Truck Range. Due to the vers, VP of fuel cells and data solutions for series will now be tested implementation, ports, along with the heavy Hyster. “As a result, trucks will continue to with electric motors. industry, can retain low costs of ownership, achieve full shift performance.”

56 M AY 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com EnerSys unveiled virtually maintenance- free lead-acid batteries EnerSys unveiled the expanded Nex- ally maintenance-free power solution Sys battery line, featuring proprietary and the means to lower their total cost Thin Plate Pure Lead (TPPL) technol- of operation.” ogy that can fast charge in just under NexSys batteries do not require an hour and be opportunity charged to equalization or watering, reducing work for up to 16 hours. labor and over-watering risks. Ideal for According to Chad Uplinger, VP of use in multi-shift operations, NexSys sales, this fl exibility opens up several batteries can eliminate the need new charging options for a range of for battery change-outs and battery materials handling applications. changing room requirements. “We’re excited to bring higher capacity Additionally, a NexSys iON bat- VP of sales Chad Uplinger with TPPL battery options to the Americas,” tery—an advanced lithium-ion solu- the new NexSys, a line of lead- Uplinger said. “Operators of Class I, II tion—is scheduled for launch in late acid batteries that do not require and III vehicle fl eets now have a virtu- 2018. watering or equalization.

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mmh.com MODERN MATERIALS HANDLING / MAY 2018 57 MODERN productivity solution

By Josh Bond, Senior Editor

Flexible panel reduces dock door panel repairs and replacements Concerns about repeated impacts from forklifts is significantly diminished.

ithin Propak Corp,’s 65,000-square-foot W warehouse in Kansas City, Kan., five forklifts handle 500 trailer transactions per week spread among 11 dock doors. The conditions create a high degree of operational risk, and plant manager Trevor Walker found that frequent forklift dock door impacts required replacement of bottom and intermediate panels twice a month. As a result, his repair and replacement costs had risen to about $1,000 per month. After installing durable high-impact polymer door panels (APS Resource, apsresource.com), the company reduced maintenance costs and operational slowdowns. “I was trying to find a solution to the recurring panel damage so it wouldn’t happen anymore,” “The new door panels have not only greatly

Walker says. “I needed to eliminate the problem.” reduced my repair costs, but they have also boosted In May 2017, Walker tried one door panel the safety on my loading dock,” Walker says. “The on the dock door with the highest traffic vol- product is definitely doing its job.” ume. From May to September 2017, he closely Walker is aware that the high volume of daily monitored the new door panel’s performance as traffic will result in human error, which is simply it withstood repeated abuse. Once the trial stage the nature of the industry. Although forklifts are concluded, Walker laid out a budget that allowed still hitting the dock doors, the new panels and the him to add one high-impact panel per month to doors themselves have yet to succumb to what his dock locations. Walker calls “the nature of the industry.”

58 M a y 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com MODERN productivity solution

By Josh Bond, Senior Editor Vertical lift module recovers 92% of storage space Shuttle VLM increases order fulfillment productivity by 460%.

ounded in 1986, Diversco Supply is a lead- “It was a complete transformation from a manual Fing Canadian equipment wholesaler in the gas picking environment of walking and searching to a industry. To position itself for growth, the company semi-automated process,” said Huddle. “The compact sought to expand into additional business segments, storage, time savings and ease of use completely offset including water sports equipment and supplies. After the cost of the system.” installing three vertical lift modules and inventory The three VLMs occupy less than 360 square feet—a management software, the company expanded inven- 92% floor space savings. The system enabled an 84% tory while reducing storage space increase in large item inventory. Large and boosting productivity. item storage previously handled eight The company’s Cambridge, containers of inventory per season, now Ontario, warehouse is the largest of it handles 50. six throughout Canada and invento- Labor requirements have remained ries and distributes parts and sup- the same, with five full-time workers plies for four business segments: (one in the small parts VLM area, two propane and gas, compressed air, in the large item rack area, and two in scuba and water sports. Manag- shipping). Productivity increased from ing a combination of smaller parts 25 lines per hour to 115 lines per hour (valves, regulators, hoses, snorkels, —while adding a bag and tag step—a fins, etc.) and large parts (kayaks, 460% increase in productivity. paddle boards, etc.) added another Using pick-to-light technology, layer of complexity to the fulfilment the transaction information center process. As the 52,000-square-foot located on the front of the VLM units warehouse ran out of space, James in combination with the laser pointer Huddle, purchasing and operations located inside the workstation direct the manager, looked to take advantage of vertical space. operator to the exact location within the tray from which “With a 40-foot ceiling, adding more rack didn’t to pick. While the operator is picking this item from the make sense,” Huddle says. “It was more economical to VLM and putting it into the individual orders on the go up than out.” batch station, the other VLMs are retrieving additional Small parts inventory was previously stored on 5,000 inventory required for the batch of orders. square feet of shelving. Using handheld RF scanning Diversco has a small amount of walk-in orders they technology, workers would walk through the shelving accommodate within the picking process. To handle scanning and picking parts as directed by the RF gun, this, they use the hot pick module within the inventory with each worker often walking several miles per day. software. This allows the operator to suspend the batch Diversco now uses a combination of three 32-foot- picking order they’re working on to pick another hot order, tall shuttle vertical lift modules (VLMs) with inventory usually for a waiting customer. management software (Kardex Remstar, kardexremstar. “Even though walk-ins represent only about 5% of com) to manage 4,500 SKUs of small parts inventory and our orders, it was critical to our customer commitment standard rack and shelving with handheld RF scanning that we had a way to fill these orders quickly and effi- technology for 400 SKUs of large item inventory. ciently,” said Huddle. mmh.com MODERN MATERIALS HANDLING / M a y 2 0 1 8 59 MODERN productivity solution

By Josh Bond, Senior Editor

Mobile racking solution installed in existing warehouse in less than four weeks Landlocked facility boosts storage accessibility, flexibility and density.

mith Corona, a leading U.S. manufacturer of The new mobile storage racking system maximizes Sthermal labels and ribbons, faces the challenge of space through use of a moving aisle, which provides balancing sales growth and increased production with direct access to every pallet location and greatly efficient use of storage space within an existing build- reduces the number of static access aisles required. ing footprint. The company installed an automated storage infrastructure to improve inventory accessibility and create a flexible workflow. The company faced the need to store more pallets in smaller footprints, and required the flexibility to manage warehouse inventory with full accessibility. It sought to consolidate storage space by using a mobile storage system (Flexspace | Storax America, flexspace360.com) in its existing warehouse. Following the installation, the company added more revenue-generating production lines, significantly increased storage density, and created more storage flexibility. “The system enabled us to increase storage capacity, increase our production lines and Wasted aisle space is converted to usable inventory utilize our space in the most efficient manner,” says space, increasing storage density by as much as 100% Benny Bonanno, senior vice president of sales. “We while providing a low cost per pallet. also have total access to each pallet location, which “The first installation exceeded our expectations,” enables us to easily manage workflow and manufac- Bonanno says, “and we are looking to expand the turing processes.” mobile racks into other areas of our warehouse.”

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HeadAUTOMATION SURVEY: AUTOMATION SPENDING ON THE RISE

BY BRIDGET MCCREA, EDITOR AT LARGE DeckFrustrated by the lack of skilled workers and pressured by outside forces like e-commerce and omni-channel distribution, companies are looking at more automated solutions for BYLINE their DCs and warehouses this year.

Text dropcap

62 M AY 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com A SPECIAL SUPPLEMENT TO MODERN MATERIALS HANDLING

f Modern’s 2018 “Usage and Implementation and purchase intentions for automation systems I of Warehouse and DC Automation Solutions” and solutions used in warehouse and distribution reader survey is any indication, conventional center operations, the survey explored the factors fulﬁ llment equipment is rapidly giving way to an and features considered important when evaluat- infusion of automated conveyor and sortation ing automation systems and solutions for possible systems; goods-to-person picking solutions; purchase. and storage solutions, to name just a few of the The survey also looked at how warehouse innovations making their way into the modern- processes are being automated, operational areas day warehouse. that companies are looking to improve over the Conducted by Peerless Research Group on be- next two years; and overall usage and imple- half of Modern Materials Handling to assess usage mentation/upgrade plans for equipment used in

How important are each of the following when evaluating automation systems and solutions for possible purchase?

Durability/Reliability/Uptime 90% 10% 0%

Support/Service response time 82% 16% 2%

Total cost of ownership/ 81% 19% 0% ROI/Maintenance costs

Integration/Compatibility 72% 25% 3% with existing equipment

Parts availability/Risk of obsolescence 68% 30% 2%

Purchase price 62% 36% 2%

Warranty program 55% 43% 2%

Scalability 46% 50% 4%

Solutions are turn-key 45% 49% 6%

Relationship/Past experience 41% 45% 14% with vendor, provider

Innovative/Leading-edge solutions 38% 56% 6%

Green/Environmentally 22% 66% 12% friendly/Energy efﬁciency

Very important Somewhat important Not at all important Change from 2017 study

Source: Peerless Research Group (PRG)

mmh.com MODERN MATERIALS HANDLING / M AY 2 0 1 8 63 MODERN special report

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warehouses and DCs. To what extent is each process automated? The e-mail survey questionnaire was sent to readers 19% 44% 16% 15% Reporting of Modern Materials Handling in January of 2018, yield- ing 191 qualiﬁ ed respondents. Survey respondents are 12% 31% 16% 21% Conveyance all personally involved in the purchase decision process 12% 37% 14% 30% Labeling

for materials handling solutions for their companies and 6% 25% 20% 36% Replenishment work in the food, beverage and tobacco; automotive and 5% 17% 22% 49% Storage transportation; chemicals/pharmaceuticals; and fabricated metals industries (among others). 5% 30% 24% 36% Picking The companies have an average of 752 employees, 4% 23% 22% 41% Retrieval with 42% having 100 to 499 employees and 38% having 4% 33% 21% 33% Packaging less than 100 workers. Twenty-two percent of fi rms had either less than $10 million or $10 million to $49.9 mil- Fully automated Partially automated lion in annual revenues, while 11% had either $50 mil- Now manual Mostly or fully manual lion to $99.9 million or more than $5 billion in revenues. but will be automating with no plans to automate Change from 2017 study Price is becoming less of an issue As the picture of the completely connected warehouse Source: Peerless Research Group (PRG) continues to come into focus, that vision is supported by a new crop of hardware and software solutions that support and/or work in tandem with today’s workforce. And as for new systems include support and response time (82%), human capital becomes more diffi cult to recruit and retain, with total cost of ownership (TCO), return on investment these automated solutions are helping companies manage the (ROI), and maintenance costs also playing important roles in labor challenge while maintaining productivity and profi t- the selection process for 81% of respondents. And, 62% say ability. purchase price is important (compared to 71% last year). This year, companies expect to spend more on materi- Bryan Jensen, chairman and executive vice president at als handling equipment and solutions than they did last St. Onge Co., says the reduced emphasis on purchase price year, with the total average expected spend to be $1.25 million, versus $1.17 million for 2017. During the next 2 years, what areas are you looking And, 34% of fi rms will spend less to improve in your warehouse/DC operations? than $100,000; 18% say they will spend $100,000 to $499,999; 13% 2017 2018 Change from 2017 study 66% say they will spend $500,000 to 65% 64% 63% 60% 60% 61% $999,999; and 16% want to spend 58% 57% 50% $1 million to $2.49 million. In most 48% 44% 42% 43% cases, companies procure their order fulfi llment solutions direct from manufacturers (70%) or from distributors/dealers (60%). When evaluating automated Labor Warehouse Order Picking Throughput Order Order solutions, most of Modern’s readers reduction capacity accuracy efficiency cycle time fill rate utilization (lines picked/ (90%) said durability, reliability, hour) and uptime were their top criteria. Source: Peerless Research Group (PRG) Other key factors when shopping

64 M AY 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com “We create solutions that feel better, ﬂow better, and just plain work better.”

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What conventional equipment is presently in use in your organization and which will you be upgrading or implementing during the next 24 months? In use Plans to upgrade/implement

94% 55% 93% 2017 2018 Lift trucks 88% 13% 85% 82% 40% Rack and shelving 74% 25%

38% Dock equipment 25% Will upgrade 38% Palletizers, pallets/totes, Will bins, containers 31% implement 38% 38% Hoists, cranes, 17% and monorails 59% Rack and Lift trucks Dock Palletizers, Hoists, cranes, shelving equipment pallets/totes, and monorails bins, containers Source: Peerless Research Group (PRG)

What automated equipment is presently in use in your organization and which will you be upgrading or implementing during the next 24 months? In use Plans to upgrade/implement 55% 52% Conveyor and sortation systems Conveyor and sortation systems 64% 34%

Weighing, cubing and 55% Weighing, cubing and 42% dimensioning equipment 52% dimensioning equipment 39%

Goods-to-person picking 38% Goods-to-person picking 38% solutions (donor totes are 47% solutions (donor totes are 34% delivered to a worksation) delivered to a worksation) Automated storage including, 24% Automated storage including, 37% AS/RS, mini-loads, AS/RS, 30% AS/RS, mini-loads, AS/RS, 52% carousels and vertical lifts carousels and vertical lifts 25% 37% Automated packaging solutions Automatic guided vehicles (AGVs) 28% 39%

Robotics–palletizing, 20% Shuttle systems and/or mobile 35% picking or other solutions 22% robotic storage and retrieval 43% systems, such as OPEX Shuttle systems and/or mobile 10% 35% robotic storage and retrieval Pocket sortation systems, such as OPEX 22% 31% 16% 2017 35% Automatic guided vehicles (AGVs) Automated packaging solutions 19% 2018 57%

15% 35% A-frame picking technologies Robotics–palletizing, 14% picking or other solutions 46%

14% 33% Pocket sortation A-frame picking technologies 14% 33%

Change from 2017 study Will upgrade Will implement

Source: Peerless Research Group (PRG)

66 M a y 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com MODERN special report

is an interesting trend that he’s also seeing fulfi llment operations, 6% of survey right now in the market. Automation as a respondents say their order fulfi llment whole has also been considered “forward is fully automated (versus 5% last year); thinking,” he says, and as such, purchase 53% say they have a mix of automated price tends to make or break the business and manual operations (52% last year); cases for these investments. “Everyone and 39% say they are mostly or all wants an ROI; they want payback,” says manual (down from 41% last year). Jensen, who credits the labor shortage In looking at the areas of the ware- with eroding some of the emphasis on house or DC they’re planning to improve payback. “Whether real or imagined, the over the next two years, 57% of readers labor shortage seems to be driving their say throughput (versus 48% last year); willingness to invest.” 66% say labor (60% in 2017); 58% feel More specifi cally, Jensen says fi rms are picking effi ciency should be the biggest tar- likely looking more closely at how they get for improvement (versus 63% last year); may have to pay $3 to $5 more per hour and 44% have their eyes on order cycle to maintain current staff levels, bring in times (50% in 2017). fl ex workers, or fi ll positions during peak To manage order fulfi lment, 91% of season—an expensive proposition in a readers are using warehousing and storage world where human capital is becoming (up from 86% last year); 69% use case and scarcer. “If companies weigh it out and see mixed case fulfi llment (up from 57% last that their [traditional] strategies are going year); 69% currently use full and mixed to be more expensive,” he says, “then some pallet load fulfi llment (up from 59% last will just make the leap to automation.” year); and 69% use individual pick, pack and ship wholesale distribution fulfi llment The current state of (up from 64% last year). Those companies warehouse automation that have upgrades planned over the next In looking around at the current state 24 months intend to use warehousing and of their warehouses, survey respondents storage (38%); case and mixed case (40%); said the highest percentage of automa- or full and mixed pallet load fulfi llment tion was being used for reporting, where (41%). 44% of operations are partially automated, 19% are fully automated, and 16% What is everyone using? are planning to automate in the near When it comes to conventional equipment, future. This represents an upward trend 94% of companies are currently using rack over 2017, when 31% were partially and shelving, while 40% plan to upgrade automated, 12% were fully automated, that equipment in the next two years, while and 21% had no plans to automate. 25% will begin implementing them. Eighty- For now, storage and retrieval remain eight percent are using lift trucks (down the “least automated” systems in the from 93% last year), and 55% are planning warehouse, with 49% saying they have no to upgrade their lift trucks in the next 24 plans to automate storage (and just 5% are months. Eighty-fi ve percent of respondents fully automated in this area) and 41% say- rely on dock equipment (up from 82% last ing they aren’t going to automate retrieval year), and 38% will upgrade their dock (where 4% are now fully automated). equipment in the next 24 months. Another Asked to describe their current order 25% of companies plan to implement

mmh.com MODERN special report

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What data collection technologies are presently in use in your organization and which will you be upgrading or implementing during the next 24 months? In use Plans to upgrade/implement 89% Mobile/Wireless 46% Bar code scanners 84% technologies 32%

Mobile/Wireless 67% Voice-directed 45% technologies 70% picking technologies 42%

RF terminal 44% RF terminal 45% technologies 41% technologies 34%

Pick- or put-to-light 18% 34% Bar code scanners Will picking technologies 31% 2017 34% upgrade Voice-directed 18% 2018 Pick- or put-to-light 32% Will picking technologies 18% picking technologies 46% implement

Heads-up display/ Heads-up display/ 32% vision technologies* 16% vision technologies 56%

* Question added in 2018. Source: Peerless Research Group (PRG)

dock equipment in the next two years. To position and/or relocate goods SIMPLIFY within the warehouse, 74% of readers currently use palletizers, pallets/totes, bins and containers. Thirty-eight percent YOUR want to upgrade these systems over the next 24 months and 31% will implement these options in the next two years. LIFE Also, 38% of companies are using hoists, cranes, or monorails (the same number as 2017), and 76% of firms want to either upgrade current or implement these solutions in the next two years. On the automated side of the house, most companies (64%) say they’re using conveyor and sortation systems (versus 55% in 2017), while 52% are using SUCCESS IS EASIER WHEN YOU HAVE weighing, cubing and dimensioning equipment. And, 86% of respondents will A customer-focused supplier that understands your needs. Satisfied, loyal customers that can depend on you. either implement new or upgrade existing A diversified customer base. conveyor and sortation systems over the Increased bottom line profit. next two years, while 81% say the same TThomberth is your SINGLE SOURCE SOLUTION for less ffrustrationr and more profit. Give us a call, kick back, about their weighing, cubing and dimen- anand rest easy. It’s that simple! sioning equipment. ,*/>'0maLmk^^mG'G^pmhg%B:%.)+,*/>'0maLmk^^mG'G^pmhg%B:%.)+)1) 1))&-,,&,.0+ mahf[^km'\hf Goods-to-person picking solutions

68 M a y 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com MODERN special report

What supply chain execution software solutions are presently in use in your organization and which will you be upgrading or implementing during the next 24 months? In useIn use PlansPlans to toupgrade/implement upgrade/implement WMS (Warehouse 78%% WMS (Warehouse 49% 72% 41% management system) management system) % WCS (Warehouse control system) 34% 43% % Parcel rating system 43% 24% % 31% WCS (Warehouse control system) 37% LMS (Labor management system) 39% 37%

TMS (Transportation 39% CMMS (Computerized maintenance 37% management system) 38%% management system) 26%

17% 37% WES (Warehouse execution system) LMS (Labor management system) % 31% 35% % % CMMS (Computerized maintenance 25% 33% WES (Warehouse execution system) management system) 28% 33% % 2017 16% % 2018 33% % YMS (Yard management system) Slotting software 26% 35%

22% TMS (Transportation 33% Slotting software 25% management system) 39% % 28% 29% Parcel rating system % YMS (Yard management system) 21% 24% % Change from 2017 study% Will upgrade Will implement %

Source: PeerlessW Research Group (PRG) (i.e., donor totes delivered to a workstation) are gaining in popularity, with 47% of respondents using them, up from 38% last year. Right now, 38% of companies FALL PROTECTION will upgrade and 34% will implement such solutions in the next 24 months. FOR YOUR ENTIRE FACILITY Among the biggest shifts in this year’s Mezzanines | Pick Modules | Pallet Drop Areas | Flow Lanes | Docks | Lifts survey involved the use of shuttle sys- Standard Models and Custom Designs tems and/or mobile robotic storage and retrieval systems such as OPEX. Twenty- two percent of companies are currently using these systems versus 10% in 2017. For 2018’s survey, 35% of respondents say they plan to upgrade these solutions and 43% plan to implement them in the next two years. Automated packaging solutions are also getting more traction in the connected warehouse, where 28% of companies use them, 35% want to upgrade their current solutions, and 57% Your trusted fall protection solutions provider... plan to implement such technology over innovating facility safety for over 30 years, inside and out. the next two years. Website: www.MezzGate.com Jensen says he’s also seeing more E-Mail: [email protected] companies taking an interest in automated Mezzanine ■ 174 WESTERN AVENUE TEL (978) 768-3000 Safeti-Gates, Inc. ESSEX, MA 01929-1110 ■ FAX (978) 768-1101 shuttle systems, mobile robotic storage

mmh.com MODERN MATERIALS HANDLING / M a y 2 0 1 8 69 MODERN special report

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and retrieval, and automated packaging. He says vision trol systems (WCS); 39% are using labor management systems are also “coming into their own” right now due to systems (LMS); and 38% rely on transportation manage- the cool factor they bring to the table. According to the ment systems (TMS). survey, heads-up display/vision technologies are currently The highest percentage of readers (90%) have set their being used by 16% of respondents and are on the radar sights on either upgrading or implementing WMS over the screen for 56% of ﬁ rms. next two years. When asked the same question about their “Even the most automated shuttle system just looks supply chain management software solutions, 59% of readers like a bunch of mechanical connections to the average said they’re using enterprise resource planning (ERP), 52% person,” Jensen points out, “but when you get bots and said customer relationship management (CRM), and 45% different devices moving around, using vision systems— rely on order management systems (OMS). and literally on their own paths and not using rails—they As the nation’s labor market challenges continue to persist, just show better and look more futuristic.” and as customers expect faster and more accurate delivery levels, expect the level of warehouse/DC automation to Software solutions continue to proliferate over the next few years. In the warehouse, data collection is largely handled with Jensen expects goods-to-person, vision, and automated bar code scanners (used by 84% of companies), mobile/ mixed pallet building applications to all rise to the top wireless technology (70%), and RF terminal technolo- thanks to the need for higher productivity levels in an era of gies (41%). When asked which supply chain execution tough labor constraints. “These types of applications really software solutions they’re using, 72% said warehouse cover the bases,” he says, “by helping companies manage management systems (WMS); 43% said warehouse con- their storage, productivity and labor pain points.”

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70 M AY 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com Aigner Label Holder Corp. wApex Supply Chain Technologies

Organize Your Metal Bins & Shelving with Handheld Device Management Get control of handheld scanners, EZ•Mag™ by Aigner tablets and more with AXCESS™ • Inventory Solutions Automated Locker Solutions. They keep devices secure and tell you • Keeps metal bins/racks who’s using each one, and when it’s organized due back. Every transaction sends data to the Trajectory Cloud™ • Works with your platform, delivering real-time standard Avery® insights that improve productivity for signiﬁcant operational beneﬁts. label #5520 / #5160

Aigner Label Holder Corp. Apex Supply Chain Technologies® 800-242-3919 800.229.7912 [email protected] [email protected] www.aignerlabelholder.com ApexSupplyChain.com/AssetManagement

mmh.com MODERN MATERIALS HANDLING / M a r c h 2 0 1 8 71 Beckhoff Automation LLC Creform Material Handling Systems

Creform AGV and carts parts handling system Creform Corporation has designed and built a complete parts-handling system that consists of a Creform BST AGV Model CA-A50060-NSI and Creform built carts. The AGV works as an automated tugger that runs along a magnetic tape guidepath, slipping under stationary carts and then carrying the carts to designated stations. Creform BST AGV Tuggers can handle a 50 course, 128 command control by programming with a PC or HMI. The AGV runs on 24V DC (two 12V batteries) and typically can have 10- hours run time. The carts are built by Creform utilizing its 28mm pipe and joint system. www.creform.com

Cubiscan Datalogic

EXPERIENCED GUIDE. Rugged Performance for Warehouse and Factory Applications The SH15 Blackline computer is a rugged WITH OVER 12,000 UNITS INSTALLED AND vehicle mounted computer (VMC) as well as a 13 UNIQUE DIMENSIONING PRODUCTS, fixed mount unit. The SH21 Blackline computer EXPERIENCE IS OUR GUIDE. is an industrial computer designed for a wall SH21 Blackline or fixed mount environments. A sealed design tested to IP65/IP67 ensures operation for both computers in the toughest environments. The Capacitive Touchscreen features a 3 mm anti-glare armored glass which can be used even when wearing gloves. Adding a hand held bar code scanner such as Datalogic’s PowerScan™ SH15 Blackline CUBISCAN 9500 reader allows for quick data entry and 801.451.7000 location confirmations. [email protected] www.datalogic.com

Dematic Douglas Battery

We take great pride in delivering great power. Douglas Battery delivers reliable power, customer support and innovative battery and charger solutions to meet the high demands of today’s material handling and airport ground support equipment applications. The innovative Legacy ® battery line provides solutions to maximize power and performance while minimizing maintenance and downtime, while our high frequency and rapid chargers are meeting the needs for higher efﬁciency, Order Fulfillment Solutions ﬂexibility and reliability across a range of industries and Low – Mid – High Capacity applications. dematic.com

www.douglasbattery.com

72 M ARCH 2018 / MODERN MATERIALS HANDLING mmh.com EnerSys Gamber-Johnson

POWER WHEN YOU NEED IT EnerSys® continues to redefine innovative power solutions with the expansion of the NexSys® battery product line. Featuring exclusive Thin Plate Pure Lead (TPPL) technology, the NexSys battery portfolio now includes configurations that can fast charge in just under an hour and be opportunity charged to work for up to 16 hours. That flexibility opens up a broad range of long life charging options for Class I, II and III applications, including high-capacity lift trucks. NexSys® batteries are virtually maintenance free and provide the flexibility to use them whenever you want and recharge them whenever you can – during breaks or at the end of the shift. www.enersys.com

Hawker Honeywell Intelligrated

THHE HAAWKKER® The Connected Distribution Center Today’s distribution centers need solutions that help them achieve maximum throughput, day-to-day ﬂexibility, future-proof scalability and actionable intelligence. The Connected Distribution Center drives the digital transformation by providing: • Intelligent, data-driven, high-speed execution • Automated, adaptable processes for machines and workers • Maximum footprint utilization, with the ability to seamlessly expand VISION. LEADERSHIP. INNOVATION. SOLUTIONS. • Insights and predictive analytics, from sensors to the cloud Join the Power Revolution. Call 1.877.7HAWKER today. Honeywell Intelligrated 866-936-7300 www.hawkerpowersource.com Intelligrated.com © 2018 Honeywell Intelligrated. All rights reserved.

Hytrol ID Label, Inc.

NO MORE SCRAPING! New Removable Warehouse Label

™ The dust may settle after MODEX, but we s Clean Release rack and shelf labels adhere REQUEST SAMPLES tightly to virtually any surface but are easy to won’t. We used four days at the greatest supply remove and reposition – even years later.

chain show on earth to show what we’re s Quickly relabel bay and bin locations to capable of: quality solutions and relationships. accommodate product inventory changes or reconﬁgurations. The supply chain never stops; neither will we. When We Do the Barcodes, s Learn why Clean Release™ was a ﬁnalist for You Can Do More 2018 MHI Innovation Award the . www.idlabelinc.com

mmh.com MODERN MATERIALS HANDLING / MARCH 2018 73 Knapp, Inc. Lenze Americas

Shuttle Technology Leader KNAPP Introduces Major Innovation! Lenze Americas, based in Uxbridge, MA, is a subsidiary of Lenze SE in Germany, a global leader in industrial KNAPP launches a revolutionary new shuttle automation systems. As a manufacturer of electrical and technology, the OSR Shuttle™ EvoWKDWLV mechanical drives, motion control and automation technol- IOH[LEOHVFDODEOHKLJKO\UHOLDEOH±DQGLQFUHGLEO\ ogy, Lenze’s solutions are found in many material handling XQLTXH applications: roller and belt conveyors, rotary and scissor lift tables, lifting stations, palletizing systems, storage and 7KLVPDMRULQQRYDWLRQGHOLYHUV retrieval units, monorail overhead conveyors and AGV 8QSDUDOOHOHGVSDFHXWLOL]DWLRQDQG systems. Our drive and automation solutions guarantee energy savings a smooth connection to any upstream or downstream 0HUJHDQG0DQDJHUHVHUYHVWRUDJH system—steady or dynamic, lifting or lowering, moving or IRUZDUGSLFNLQJDVRQHHFRV\VWHP positioning—increasing the productivity of your logistic systems. 0RGXODUVFDODEOHGHVLJQ 6HTXHQFLQJWRPXOWLSOHDQGGLYHUVHZRUN KNAPP Inc. | knapp.com VWDWLRQVURERWLFSLFNLQJ±HYHQKLJKVSHHG Lenze Americas SDOOHWL]LQJ±ZLWKWKHVDPHFRUHV\VWHP 508-278-9100 800-217-9100 www.Lenze.com

Lewco, Inc. Lind Electronics, Inc.

DISTRIBUTION -COMMERCE RETAIL E conveying technology is designed to support Freight optimization is driving the industry to ship smaller packages at faster speeds. LEWCO Red this challenge. LEWCO RED Conveyor Technology helps facilitate: • Dock Delivery, Smalls Sort, Edge alignment, Sortation, products Singulation, are built to Zoneorder, Accumulation, Gapping, experience Merging, designing Splitting,conveyor andTransport manufacturing Belt conveyors. LEWCO has extensive equipment for RED industries. Our based on your speciﬁcations, in a wide range of sizes and options. Contact us today staff to discuss of Application your RED Engineers equipment will requirements. assess your application Our knowledgeable needs and recommend a cost-effective solution, built to the highest industry standards.

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OPEX Corporation PFlow Industries, Inc.

Smart, Streamlined Order Sortation Sure Sort™, the only automated put wall of its kind, provides a better way to sort items accurately and efciently. Featuring a compact array of vertical sort locations in a small footprint, Sure Sort reads an item’s barcode(s) regardless of orientation, and delivers each item in a single pass. Its exclusive iBOT® technology helps increase throughput and reduces labor.

OPEX Corporation 305 Commerce Drive Moorestown, NJ 08057- 4234 opex.com

74 M ARCH 2018 / MODERN MATERIALS HANDLING mmh.com Raymond Corporation Rite-Hite

2018 MHI INNOVATION AWARD WINNER

RAYMOND VIRTUAL REALITY SIMULATOR Take safety at the loading dock to a new level. TM Experience a new reality of enhanced operator The newly expanded Rite-Vu system provides instruction at raymondcorp.com/VR. additional layers of safety far beyond securing trailers at the loading dock. It helps protect people on and off of forklifts, with hazard recognition and control options. Booth #1747

Schaefer Systems SICK, Inc

Camera, RFID & Laser Solutions from SICK

With SICK you have a choice when it comes to automatic identification, including camera and sensor solutions for code reading, dimensioning, conveyor control, track and trace, AGV/AGC guidance and much more! Plus, find out how SICK can optimize your DC with device to cloud solutions for true Industry 4.0 readiness.

800-325-7425 [email protected]

Swisslog Van der Graaf

NEW Intelligent Drum Motor (IDM) technology delivers an exceptionally high continuous torque profi le, full speed and indexing control and signifi cant energy effi ciency gains over traditional induction motors. Because the magnetic fi eld of the rotor does not have to be magnetically induced, effi ciency gains of up to 70% can be achieved in both no load and fully loaded conditions compared to conventional induction motor and gearbox combinations. This results to higher torque and horsepower within the same frame size and the ability to use a smaller drum motor with IDM technology in equivalent applications for even further effi ciency gains.

ADVANCED, GOODS-TO-PERSON AUTOMATION SOLUTIONS Van der Graaf (888) 326-1476 • [email protected] www.vandergraaf.com

mmh.com MODERN MATERIALS HANDLING / M ARCH 2 0 1 8 75 FOCUS ON Dock Equipment

Automated detection system protects workers on docks The Rite-Vu Light Communication Systems family offers two new products that reduce the risk of worker injury at loading docks: Pedestrian-Vu for the dock’s interior and Approach-Vu for its exterior. Inside, Pedestrian-Vu uses motion- sensing technology to initiate the projection of a bright blue light onto the dock leveler when it detects materials handling equipment or a pedestrian’s presence inside the trailer. Outside, from a fixed location above the dock door, the Approach-Vu sensor detects the motion of a tractor-trailer backing into a dock position. Both devices interface with the Dok-Lok vehicle restraint to trigger a visual and audible alarm that alerts dock workers and pedestrians in the drive’s approach of the impending danger. Rite-Hite, ritehite.com.

Keep workers in dock areas cool with high-volume, low-speed fan Offered in diameter sizes from 8 to 24 feet, the I-Class industrial high-volume, low-speed (HVLS) fan moves large amounts of air while generating energy savings. The fan produces a gentle, 2 to 3 mph breeze equivalent to a 4°F to 7°F reduction in perceived temperature. In testing, the 24-foot diameter fan improved airflow in a coverage area of 30,000 square feet. The fans also reduce stagnant air, alleviate hot and cold spots, and keep perishable food dry and fresh. All may be specified with a variety of customizeable options, while control choices range from individual control to small-group networking to integration into a building management system. Entrematic, entrematicfans.com.

Abrasion resistant fabric reduces wear, extends dock seal life ArmorGuard ADS-HP and ADS-HC loading dock seals feature super high abrasion resistant compound (SHARC) fabric to prevent damage from movements caused by air ride suspensions and intermodal trailers as they rub against the devices. The fabric has been tested and certified to withstand more than 40,000 abrasion cycles and to deliver as much as 10 times the abrasion resistance of competitive fabrics. For further seal longevity, the HP model is equipped with the supplier’s Wear Master Head Pad with a full width wear face and 4-inch exposure wear panels, while the HC model uses 1 x 3-inch encapsulated foam chambers in its head curtain to further improve the seal against trailer tops. Kelley, kelleyentrematic.com.

Conserve energy with insulated, sectional dock door The TKO VertiCool sectional dock door is engineered for use with vertical storing dock levelers. In addition to minimizing energy use, the door is also more cost effective than a standard sectional door and more cost efficient than a vertical rise freezer door. Its 48-inch-high panels feature 4-inch thick, R32-rated insulation. Other energy-efficient highlights include dual compression seals on three sides and a full opening polymer thermal break track. Assa Abloy, assaabloyentrance.us.

76 M a y 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com FOCUS ON Dock Equipment

Low-profile breakaway dock door repairs itself after an impact Ideal for cold storage, food and beverage operations, manufacturing and warehousing, the Turbo-Seal SR dock door repairs itself automatically—bringing the door panel back into its track without manual interven- tion—and resumes full operation after an impact. Made of two-ply fabric, the door offers extra-high-speed operation that also minimizes the potential for doors to get hit. Other features include a full perimeter seal to separate environments and counterweighted operation that reduces motor wear and extends the life of the door. Doors can be built to accommodate widths up to 12 feet and heights of 15 feet. Rytec, rytecdoors.com.

Span the gap between dock and trailer with dock leveler Two different dock leveler models provide an easy way to span the gap between a dock and truck bed. Easy to install and use, the Edge of Dock leveler mounts to the face of the dock to provide a ±5-inch service range for forklifts transitioning from the dock into the truck. The leveler can be welded to an existing steel channel or to an optional approach plate. For applications that need to reach further into a truck, the Lo-Dock leveler mounts to the top of a dock and raises its height to a level that easily reaches into trailers. It handles loads up to 30,000 pounds and comes in three widths (66, 72 and 78 inches). Bluff Manufacturing, bluffmanufacturing.com.

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1-800-328-8456 www.industrialnetting.com mmh.com MODERN MATERIALS HANDLING / MAY 2018 77 FOCUS ON Dock Equipment

Vehicle restraint with new sensor bar verifies connection to RIG Recently updated with a rear impact guard sensor bar, the Stop-Tite vehicle restraint automatically detects and ensures that the device’s arm is securely connected to the RIG. This prevents the vehicle from leaving the dock until all personnel and forklift vehicles have cleared the trailer. The unit comes in manual and automatic models, and it can be installed with a light communication package to alert the truck driver and dock workers when it’s safe to begin the loading or unloading process. McGuire, wbmcguire.com.

Consolidate multiple hydraulic Dock warning signal alarm with levelers with one system optional IoT connectivity To reduce the cost of operating six or more hydraulic Recently updated with optional fea- loading dock levelers, the CentraPower system consol- tures that facilitate Internet of Things idates individual electric motors, pumps and levelers (IoT) connectivity, the Safety Sentry into a single pumping station. The system cuts energy warning signal alarm improves dock usage as well as reduces the amount maintenance pre- safety by alerting anyone nearby of a viously required to service the hydraulic system at each vehicle backing into the dock position. individual leveler. Easy to The system can now be equipped with install, the system comes a built-in Wi-Fi 2.4GHz, RF 433MHz with a backup pump and smart switch that enables it to be powered on and off motor to ensure reliable at set pre-determined times, such as when a facility is operations. Poweramp, closed. Using a siren and strobe light, industrial motion poweramp.com. sensors trigger the device when they detect vehicle movement. For durability, it is housed in an ultraviolet light-resistant polycarbonate housing rated NEMA 4 with liquid-tight strain relief connections. Erich Dock shelter withstands abrasions Industries, docksafety.com. for long lifespan Incorporating ultra high wear resistant (UHWR) fabric that withstands abrasive movement caused by air ride suspensions and intermodal trailers, the Blackout BDS-S Store dock plates dock shelter offers a long lifespan. The shelter has been with rack device tested and certified to with- Recently introduced, the DPR- stand more than 40,000 abra- 2616 dock plate storage rack sion cycles. To further block provides a safe way to store moisture, air and light from heavy and awkward-sized dock entering a facility, the unit fea- plates when not in use at ship- tures the supplier’s DryDock ping and loading docks. The ver- integral rain header system tical height of the rack protects that stops moisture infiltration the plates while holding them from the top of a trailer; the securely. For long-term durability, the rack is con- Hinge Guard to seal off the structed of steel with a smooth finish. It installs with hinge gap around swing-out doors and prevent air and a simple bracket attachment to a designated surface light from entering a facility; and the LightBlockr connec- for stability; to help with placing and removing the tor curtain that inhibits air and light infiltration at overlap dock plates, the bracket also includes a roller. Vestil of side and head curtains. Serco, sercoentrematic.com. Manufacturing, vestilmfg.com.

78 M a y 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com FOCUS ON Dock Equipment

Drive-away prevention device To eliminate risk and human error while ensuring worker safety and increasing loading and unloading efficiency, Salvo glad-hand dock safety systems interlock a trailer’s air brakes with the dock door, preventing drive aways. Once the device is applied to the trailer’s air brakes, a uniquely coded key is released for inser- tion into the dock door lock. When the door opens the key is trapped, ensuring that it remains open during all loading and unloading activities. When complete, the dock door is locked closed, the key released and inserted into the device for removal from the air brakes. The driver then reconnects the air brakes and can drive away safely. Kirk Key, kirkkey.com.

Improve safety and communication with dock workers Incorporating the Edge Lights communication system with a vehicle restraint at the loading dock increases operator safety by providing a clear indication to dock workers when it’s safe to enter the trailer. The light system installs along the edges of the top corners of the dock door for maximum visibility. When the trailer is secure, they flash green; when an unsafe condition exists, the lights illuminate in red. Allied Solutions, allieddocksolutions.com.

mmh.com MODERN MATERIALS HANDLING / M AY 2 0 1 8 79 mmh201703_Durabelt_qtr.indd 1 2/27/2017 10:36:25 AM FOCUS ON Dock Equipment PRODUCT Showcase

Aluminum loading ramp works with Powered mobile multiple surface angles, textures workstations for Offered as a low-cost, maintenance-free alterna- manufacturing tive to hydraulic lift gates and fixed dock ramps, assembly lines WM System loading ramps connect vans, box Newly launched, a line trucks and trailers to a dock for loading and unload- of flexible manufacturing. They handle load capacities between 880 and ing workstations combine 4,000 pounds, and they can be stowed vertically. industrial worktables Manufactured of aluminum, the ramps feature and advanced lithium ion ridged or shot-blast, anti-slip surface textures to storage technology from improve traction on inclined surfaces while minimiz- two suppliers. The workstations come in a variety of ing the risk of injury from a loss of footing. Ramps sizes and can be customized with adjustable height, may be specified fans, programmable switches, monitor mounts, anti- in two-panel con- vibration leveling mounts or casters and up to 30 amps figurations with of 120-volt AC power that supports any traditional lengths from 98 hand assembly tool. For high energy density, the 6.7 to 128 inches, kilowatt-hour power system eliminates the need for or in three-panel hard wiring and enables the workstations to be mobile. configurations Other highlights include fully automated control in lengths up to 15 feet. To accommodate multiple and monitoring of monitor energy supply and status surface angles and textures, the ramp ends are through CAN communication protocols. Built Systems, equipped with rollers and adjustable flaps. National builtsystems.net; Volta Power Systems, voltaps.com. Fleet Products, nationalfleetproducts.com.

Simplify loading with hydraulic or Load, unload mechanical levelers cantilever rack with counterbalanced Providing reliable operation in a choice or hydraulic walkie stacker or manual function, a line of edge-of-dock levelers Recently unveiled, the new mounts easily to the dock face for simple, effective 2,600- to 3,500-pound loading and unloading. The NL series incorporates a capacity EJG 212-216 series roller-bearing lift mechanism for easy manual lifting; of counterbalanced walkie the HNL features push-button hydraulic activation stackers are ideal for loading and with a NEMA 12 control panel that raises the plat- unloading cantilever-type storage racking, sideways form. Both hold up to 35,000 pounds and come in lifting of pallets or special load sizes where support deck widths from 66 to 84 inches. DLM, dlminc.net. arm walkie stackers cannot operate. Highly maneuver- able in tight spaces, the vehicles feature electric steer- ing and a tiller arm that assists an operator’s handling of loads with precision and minimal effort. Other highlights include low-maintenance, three-phase AC drive motor, one-year/2,000-hour parts warranty with a two-year/4,000-hour extended powertrain warranty. Jungheinrich, jungheinrich.com.

80 M AY 2 0 1 8 / MODERN MATERIALS HANDLING mmh.com Nestable, one-way plastic pallet Combining high capacity and low tare weight, a new, nestable plastic pallet is affordable for one-way shipping applications. For increased impact resistance and stable load handling, the pallet has a rib-reinforced perimeter that enables it to be used in light- to medium-duty reusable applications, for work-in-process, storage, display or distribution. Measuring 40 x 48 inches and weighing 17 pounds, the pallet supports 2,500 pounds (dynamic) or 8,800 pounds (static). It is high-pressure injection molded of recycled high-density polyethylene (HDPE) resin and features nine nesting legs with knockouts that reduce weight and cost, tapered edges to assist fork tine entry, four-way fork entry, and an open deck. One Way Solutions, oneway-solutions.com.

Modular belt conveyor ensures reliable product transfer Robust and low profile, the new Stingray modular belt conveyor employs micropitch plastic belts atop heavy-duty, 11-gauge stainless steel. Engineered to provide reliable product transfer, smooth transitions and product accumulation, the system is ideal for delicate, small footprint or unstable products that may be damaged by a conventional conveyor. It comes in modular and scalable sections up to 20 feet and belt widths from 4 to 24 inches for easy integration into virtually any floor space. In addition, conveyor sections easily accommodate 90-degree transitions for smooth, precise movement from one conveyor to another. ABCO Automation, goabco.com.

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mmh.com MODERN MATERIALS HANDLING / MAY 2018 81 MODERN 60 Seconds with...

track anything from a tin of John Hill caviar to a pallet anywhere within a company’s TITLE: Director, St. Onge network.” We now have LOCATION: Watsonville, Calif. the wherewithal to do what EXPERIENCE: 50 years in the in our naivete we thought materials handling and automatic we’d be doing by around identification industries. 1980, and it’s exciting.

Modern: What has changed? Modern: What was the state of Or, what took so long? automation, software and automatic Hill: We didn’t have all the identification when you entered the tools back then. The most industry back in the late 1960s? significant contributors Hill: Automation was afoot in to transmissions moving down an have been computing power and the warehousing and distribution, but it assembly line. I first came across related drop in the price of computing was primarily focused on movement the idea of a WMS in 1974 at the and communications networking. Now, and by that I mean conveyors. People National Material Handling show in we need to be careful not to take it were busily working on automated Chicago. I met with a guy named for granted. People see bar codes storage systems and automatic guided Vincent Occhipinti, who was a pioneer everywhere and assume they work, vehicles, but those didn’t appear until in enterprise and factory automation but there’s still a lot of dotting I’s and the 70s. Looking back, the technology software. He had founded a company crossing T’s that has to be done behind was pretty primitive, but we sold called Logisticon and was working on the scenes to make sure it works these things and they provided value. things like a wire guidance system to properly. This is a generalization that The biggest contrast between then manage narrow aisle flow. He told me has a few holes in it, but I don’t see and now is that the solutions were that if we could find a way to keep people paying enough attention to the monolithic. They addressed a single track of lift trucks and where they go, basics; they assume all this stuff works set of problems without a look into we could communicate with them. He and that’s dangerous. the future about what could derail the wanted to develop wireless terminals initiative in terms of changes in the that could be installed on the trucks Modern: How should the industry sizes of pallets and packaging. and communicate with the operators. think about innovation? At the time, I was not interested in Hill: That’s a question I keep posing to Modern: You were there at the early joining the company because I thought myself. For instance, I wonder what it stages of the bar code scanning and he was too far ahead of his time. Turns will take for us to really create an warehouse management system out, in 1975 or 1976 he sold a solution Internet of Things, a connected supply (WMS) industries. What were those to JCPenney in Southern California chain. Recently, I spent three days at early implementations like? using truck-mounted terminals that Google’s headquarters with a group of Hill: The first implementation of a could be used to input data on cartons 400 autoID types from around the bar code scanning system that was and boxes on the facility. He called it world. There were people there who not at the point of sale was Buick Dispatcher, and it was the first WMS. were focused on RFID, on bar codes Plant Number 10 in October 1971. and things like QR coding. I saw more I know this because I carried a Modern: So, what’s the state excitement about the future and what 50-pound scanner into that plant for of automation, software and they can bring to the party when it the demo. Buick wanted to improve identification today? comes to the Internet of Things and traceability, and it was an easy sale Hill: Back in the 1970s I wrote an article smart sensors than I’ve seen in a long once we demonstrated that a scanner with a lead line that went something time. I think our industry needs a little could read lines on a label attached like “Within 10 years, we’ll be able to of that excitement.

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