Pick-to-Light system

The Pick-to-Light system is a picking technology that provides an innovative light directed picking solution for order fulfillment, by which papers are not required. Thus, it helps warehouses and distribution centers to increase order picking productivity and accuracy.
By acquiring the Pick-to-Light technology, companies can expect their picking productivity to increase or even double in shelf rack picking, mobile cart picking and assembly workstations.


This link below shows the demonstration of the pick-to-light system.
http://www.workingmachines.com/p/pick-to-light-demo-popup.html

Why is it better to use a computerized system rather than a paper-based system?

- Very inefficient.

Unit Load Formation Equipment

Because of the increase in demand from the customers, it has always an issue to transport all their orders in the least number of trips to maintain low transportation cost. Unit load formation equipment used to restrict materials so that they maintain their integrity when handled a single load during transport and for storage. Furthermore, by packing small number of goods for shipment into one unit, damages and pilferages of these goods aer kept to a minimum. By unitisation, it is less strenuous to unload or load goods packed in standard large loads than in different kinds of packages. Standard handling and storage equipment like the forklift can be used as goods are palletised into a single unit. Below are the unit load formation equipment that are use in different situation.

1. Pallets



These platforms are usually made from wood or plastic that has enough space beneath the top surface to allow the forklift to insert its fork for lifting purpose. Other types of material that is use to make pallet includes paper, metal as well as rubber. These pallets normally come in the measurement of 1200 X 800 mm. This is the standard pallet measurement in Europe as it is compatible with most railcar and truck trailer.

2. Tote Pans



Tote Pans are usually made from metal or plastic. They are reusable containers that use to load up loose discrete items that need more protection against rough handling. Tote Pans are usually used for in process-handling. However, they can replace cartons and being use for distribution as well.

3. Pallet Box



These wooden/metal/plastic boxes are being intact to pallets, therefore called the pallet box. Having a pallet intact below would means that they can be lift by forklift easily. They are reusable containers that are use when there are loose items that need protection from fork/platform truck handling.

4. Bins/Baskets/Racks



These are storage equipment that are use to store loose item in the warehouse itself. They are usually being transfer to other storage equipment like pallet box when it is distributed.

5. Cartons



They are disposable containers that are use for distribution. Given its weight, they are the most commonly used storage equipment. The dimension of the carton come is varies depending on the situation. These cartons are usually place on pallet and transfer to vehicles via forklifts. Because of its flat surface, they can be easily stacked when needed.

6. Bags



Made from paper or polymerized plastics. These containers are very light in weight however does not give much protection for its items. They are usually being pack together in a bigger container like carton or pallet box so take they can be stackable.

7. Bulk Load Container



This is a reusable container that can be use to store solid and liquid items. This storage equipment includes drums and cylinders. They can be both use for in-processing handling and distribution.

8. Crates



Often made from wood, this storage equipment is usually use to transfer large size and quantity items.

9. Strapping Tape



Make from either plastic or steel. These are use when the items need to be stabilized. In other words, the items are tied to prevent them from being loose with transporting them.



During stretch wrapping process, items will be wound around by film to prevent irregular shape item to be loose during distribution.

Walkie Truck

Low-lift pallet trucks are the most widely known Walkie trucks that are self-loading and equipped with wheeled forks of dimensions to permit the forks to go between the top and bottom boards of a double-faced pallet. The wheels are capable of lowering into spaces between the bottom boards so as to raise the pallet off the floor for transporting.

This unit allows the operator to ride on the truck, yet also permits off-truck maneuvering by the operator.
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High-lift Pallet Trucks are capable of self-loading. They are equipped with an elevating mechanism designed to permit tiering.

One type of high-lift pallet truck is a counterbalanced truck. This is a truck equipped with a load-engaging means wherein the load is suspended forward of the front wheels. With this design the truck can handle single and double-faced pallets, skids, and bins.

Another type of high-lift pallet truck is straddle trucks which may be defined as trucks with a horizontal structural member supporting wheels extending forward from the main body of the trucks. These trucks are designed to operate in narrow aisles as compared to a counter-balanced truck.

Walkie high-lift pallet trucks are also available as 'fork over arm' truck. This truck is a non-counterbalanced truck. The forks are placed directly over the load wheels and are limited to only handling of single-faced pallets, skids, or bins.
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The Walkie reach truck is a self-loading truck which can be extended forward under control to permit a load to be picked up and deposited in the extended position and transported in the retracted position. This truck has an advantage over the straddle truck in that pallets of various widths can be handled and stored close together. This is because the base arms do not enter the rack sections which means the truck can be used with any existing rack installation.(high flexibility)

Preventing injuries and deaths of workers who operate or work near forklifts

The National Institute for Occupational Safety and Health (NIOSH) requests assistance in preventing injuries and deaths of workers who operate or work near forklifts.

NIOSH investigations of forklift-related deaths indicate that many employers may not be aware of the risks of operating or working near forklifts. They may not follow the procedures set forth in the Occupational Safety and Health Administration (OSHA) standards, consensus standards, or equipment manufacturer's guidelines.

NIOSH requests that editors of trade journals, safety and health officials, industry associations, unions, and employers in all industries bring the recommendations in this Alert to the attention of all workers who are at risk.


Employee
- Make sure that workers do not operate a forklift unless they have been trained and licensed.

- Develop, and implement a comprehensive training program to protect and prevent injury and death.

- Inform and instill the danger to the workers of operating or working near a forklift.

- Wear a helmet at all times.


Employers should take note:
- Conduct pre-operation safety inspection on horn functions, steering mechanism with engine running, seat break, clutch and hydraulic control.

- Be extra careful when driving the forklift to conduct picking or loading.

- Make sure forklift is charge before use (Minimum charge should be ½ capacity or ¾ for heavy load).

- Do not operate a forklift unless you have been trained and licensed.

- Use seatbelts when driving forklift if they are available.


Precaution to be taken under consideration when driving forklift truck:
- Be aware of obstacles, both ahead and overhead.

- Be cautious about cable trays.

- Move materials only in the designated areas with adequate space.

- Do not block individuals into a stack

- horn whenever you are unsure of oncoming traffic, intersections or when reversing (Vision obstructed).

- If you cannot see well, have a spotter.

- Loads should be lowered for stability and to increase the vision of obstacles.

- Do not raise or lower the forks while the forklift is moving.

- Operate the forklift at a speed that will permit it to be stopped safely.

- Do not allow passengers to ride on forklift trucks unless a seat is provided.

- Never travel with load in raised position.


Safety Consideration for Workers on foot:
- Should be separated from the forklift traffic where possible.

- Limit some aisles to workers on foot only or forklifts only.

- Restrict the use of forklifts near time clocks, break rooms, cafeterias, and main exits, particularly when the flow of workers on foot is at a peak (such as at the end of a shift or during breaks).

- Evaluate and improve the visibility of forklift operators or workers on foot.) etc, fix more mirrors at any corners or blind spot)

- Make every effort to alert workers when a forklift is nearby. Use horns, audible backup alarms, and flashing lights to warn workers and other forklift operators in the area. Flashing lights are especially important in areas where the ambient noise level is high.

here are some videos to show on some of the safety precaution to be taken under consideration.





and here are some of the "No No" ways to drive a forklift.
Please do not learn


the driver should not drive so fast when he knows he is surrounded by goods.



in the first place, the driver should be lowered the loads for stability and not to move when the loads are at the highest point. it might cause the forklift to flip in worst case senario.

Types of common forklift truck

Forklift truck is a powered industrial truck used to lift and primarily to move materials stored on pallets.

Following is the list of the more common truck types, from the smallest to the biggest;

1. Hand pallet truck - a simple mechanism whereby hand-pumped hydraulics raise or lower a single pallet simply to provide clearance from the floor.


2. Walkie low lift truck - powered pallet truck, usually electrically powered


3. Rider low lift truck


4. Towing tractor


5. Reach truck small forklift - designed for small aisles, usually electrically powered)

Conveyor

Conveyors are extremely useful in the transportation of heavy items. They are very popular for industrial uses as materials can be efficiently transported.

Conveyors are used:

- When material is to be moved frequently between specific points (for an example, from picking to packing)
- To move materials over a fixed path
- When there is a sufficient flow volume to justify the fixed conveyor investment

Conveyors can be classified in different ways:

- Type of product being handled: unit load or bulk load
- Location of the conveyor: overhead, on-floor, or in-floor
- Whether or not loads can accumulate on the conveyor

Many companies favor the usage of conveyors, as firstly, they are much safer to operate rather than operating forklifts or any other kinds of machinery.

Industries minimize the cost, as manpower can reduce with the aid of conveyor. Conveyors allow the movement of all kinds of materials ranging from different weights, sizes and shapes, which many other forms of transport cant conform with.

There are many different kinds of conveyor systems used nowadays. They are the belt conveyor, line shaft roller conveyor and chain conveyor. The belt conveyor consists of a belt, pulley and rollers. When one of the rollers rotate, it will cause a forward movement of the belt which will in turn move the materials on it forward. Belt conveyors are not usually used for bulky materials but for grocery products such as vegetables.

Line shaft roller conveyors are for light materials up to 20kg. The conveyor consists of rollers, shaft and an electric motor controlled by electronic programmable logic controller. The advantages of using this type of conveyor are that it is easy to install and maintain, it doesn’t make much noises and lastly the constructing of it doesn’t requires much capital. Although it has these advantages, not many industries use these types of conveyors. It can only move objects of certain shape as objects moved along this conveyor may fall between the rollers. Chain conveyor is different from the other 2 conveyors. It can transport heavier goods and is commonly used in the car production line.

Those conveyors are some of the example that can be seen in our daily operation.

Following up will be some of the conveyors used in handling materials in warehouse:

1. Chute Conveyor




It can be used:
- to transport Unit or Bulk items
- On-floor, used to convey items between floors
- Items can be accumulated
- to link two handling devices

Cost: Inexpensive

Disadvantage: Difficult to control position of the items

* Require precise and accurate design of inclines and configuration.

2. Skate Wheel Conveyors




It can be used:
- Only for single unit at a time
- On-floor
- Items can be accumulated
- For light-duty application with rigid bases

Uses a series of skatewheels mounted on a shaft, where load is being transported (spacing of the wheels is dependent on the load)

Cost:Economical

3. Roller Conveyors



It can be used:
- Only for single unit at a time
- On-floor
- Items can be accumulated
- May be powered (or live) or nonpowered (or gravity)
- With a minimum of three rollers must support smallest loads at all times

3.1 Gravity Conveyor Conveyors



It can be used:
- For heavy-duty applications
- Slope for gravity movement (depending on the load weight)
- Accumulating loads

This can be an alternative to wheel conveyor.

3.2 Live (Powered) Roller Conveyor




It can be used:
- For belt or chain driven
- For force-sensitive transmission to disengage rollers for accumulation (load should be smooth and firmly based with three rollers in contact at all times.)
- For accumulating loads and merging/sorting operations
- Provides limited incline movement capabilities (Inclines are not recommended)

4. Flat Belt Conveyors




It can be used:
- Only for single unit at a time
- On-floor
- For moving light cartons or cases

Disadvantage: No smooth accumulation, merging, and sorting on the belt

The belt is roller or slider bed supported. They can be made from rubber, plastic, fabric, composites of these, steel and steel-mesh.

5. Chain Conveyors




It can be used:
- Only for single unit at a time
- In/On-floor Unit
- Load on two or more sets of parallel roller chains, and are for heavy loads

Vertical chain conveyors are used for continuous high-frequency vertical transfers.

6. Slat Conveyors




It can be used:
- Only for single unit at a time
- On-floor
- Operate horizontal and inclined
- Used for heavy loads or loads that might damage a belt

7. Power and free Conveyors




It can be used:
- to transport single unit
- On-floor/ overhead
- Items can be accumulated

The power-and-free conveyor uses two tracks: one powered and the other non-powered.


there are different type of conveyor, here are some videos to illustrate.



Conveyor system from custom conveyor. Conveyor with pusher, plow, conveyor escapement stop, pull off and conveyor to conveyor transfer


so if we look into our daily lifestyle, conveyor is also used. have you tried sushi in sushi bar? where you can just retrieve what you want to eat from the conveyor? this time round, we place an camera on the conveyor.


car chain conveyor


conveyor is used everywhere.

Introduction on material handling

Have you ever thought why are equipment needed to handle material?
Or even, what is material handling?

We have found out some information to let you understand better.

According to the Britannica online Encyclopedia, “materials handling” refers to the movement of raw goods from their native site to the point of use in manufacturing, their subsequent manipulation in production processes, and the transfer of finished products from factories and their distribution to users or sales outlets.

http://www.britannica.com/eb/article-9051372/materials-handling

While we will explain as:

Material handling is required from receiving to in-storage handling and to shipping. Handling can mean activities such as loading/unloading and inspection. Whenever there is a movement of product, it requires handling.

So, in order to have efficient movement (handling) of goods, handling equipment is used.

Some of the handling equipment used in the industry:

1. Forklift Trucks.
2. Walkie-Rider Pallet Trucks
3. Towlines
4. Tow Tractor with Trailers
5. Conveyors
6. Carousels
7. Pick-to-Light Systems