Re: Lean Manufacturing and Lean Warehousing Series

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For the latest information on lean warehousing, go to www.simsconsult.com or telephone +1-740-654-1091 SECTION3 TYPTCALI{AREI{OUSE EQUIPMENT Table of Contents Fork Lift 3.1 3 . 1 . 1 General Trucks
a a a a a a

Page No.

3.r.2 3 .r . 4
3.2 3.2.L 3.2.2 3.3 3.3.1 3.3.2 3 .3 . 3 3.4 3 . 4 .r 3 . 4. 2 3.4.3 3.4.4 3.5

3 . 1 . 3 Narrow-Aisle

Counterbalance Trucks Trucks . Hybrid Trucks Storage-Retr i e v a l M a c h i n e s S e l e c t i v e S to r a g e S y s t e m s High Density Storage Systems Order Picking Vehicles Fork Truck Units Storage-RetrievalUnite .. Other Vehicles
Non-Powered Vehicles
a a a a

....

o.

Dollies . . Iland Trucks Semi-Live Ski d s . . . Trai ler s Cranes 3 . 5 . r Jib Cranes 3 . 5. 2 Bridge and Gantry Cranes 3.6 Pallet llandling Mechanisms 3 . 6 .I General 3 . 6 . 2 Turret Forks 3 .6 . 3 Flip Forks 3 . 6 . 4 Shuttle Table
a

.
a a a

.
a

.
a a

3-t 3-l 3-t 3-t 3-3 3-3 3-3 3- r 0 3- r 0 3- r 0 3- 10 3- l 3 3-r3 3- r 3 3- t 3 3-17

3-L7 3-21 3-2r

3-2r
3-24 3-24 3-24 3-24 3-26

3.1 3. I .1

TORKLIFT TRUCKS General

In the movement and storage of pallets, the relationship between the pallet and the fork truck or S/R rnachine is congtant. Ttre functional. differences among fork lift trucks and pallet handling rnachines are in the relationships between the machine, aisle size, and height of storage. In the case of fork lift trucks, the basic equipment classes may be described as folLows: 3.L.2 Counterbalanced Trucks

Conventional or counterbalanced fork lift trucks carry the pallet streight out in front of the machine on permenently aligned forke. These trucks must turn at right angles in order to place the naterial in storage (tr'igure 3-1 ). Ttrey require wide aisles (10 to 14 feet) and substantial floor capacity. They are available with both electric and internal combustion porrer. 3. I .3 Narrow-Ais le Trucks of the

Narrow aisle reach type equipment is represented by three basic categories vehicle; the straddle, reach, and side loading truck. In,etraddle trucks, (twm

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TY]PNCAN, ]R. N,A'. COUN 1I]E tsA'' NC ]E lTR.UCK

Figure 3-1

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This maA variation on the straddle Eruck is the reach truck (Figure 3-2). chine has a fork extension capability through the use of a pantograph device in racks wtrich reaches out beyond the outrigger wheels to position the pallet These rnachines perform in the same manner as the counteror on the floor. in a narrolter They operate balanced machines v*ren Ehe forks are extended. (usually 7 to 8-Il2 feet) and can make turns in closer quarters because aisle they can retract the pallet to a position within the wheelbase. Side loading trucks generally operate to one side of the aisle and place the i.e. load laterally, across the Eravel direction of the machine. These main the aisle c h i n e s c o m e i n a v a r i e t y o f d e s i g n s . S o m et r a v e l l o n g i t u d i n a l l y permanently located masts equipped with reach devices to move the forks with Some of these machines have moving nasts which add to the out from the side. extension capability and permit double depth placement of loads (Figure 3-3). Other configurations have a rotating or swing rnast which can reach out to the side (Figure 3-4); these trucks are also referred to as "front/side loaders'r. their Four-way machines (Figure 3-5) are fork lift devices r,ilrich Eurn in oqrn down J.ength and can move in any direction. These machines can move laterally Ehe aisle and place a load from Ehe side, they can operate as a conventional fork lift truck, or Ehey can operate at an angle. forks through 180 deiDhe turret type machines (Figure 3-6) can swing their grees and can load pallets from either side of the machine. These units vary in their aisle requirements and in their flexibility but generally operate in widths of 50 to 84 inches and wich clearances only slightly aisle larger than the size of the pallet itself. 3. f.4 Hybrid Trucks

veHybrid trucks (figure 3-7) cornbinethe best features of both narrolr aisle hicles machines. A typical hybrid vehicle consists of a and storage-retrieval tall rigid mast sinilar to that used on a storage-retrieval machine. The masE is equipped with a shuttle table or EurreE fork system to handle pallet loads. T h e s e p a l l e E h a n d l i n g m e c h a n i s m sa r e s i n i l a r t o t h o s e u s e d o n t u r r e t . t r u c k s . The base of the vehicle consists of a battery powered qfteeled platform which permits the hybrid truck to be driven between aisles in a manner similar to a fork truck. W t r e no u t s i d e t h e s t o r a g e a i s l e , t h e h y b r i d v e h i c l e r u n s o n i n t e r power is obtained nal batteries. W h e no p e r a t i n g w i t h i n t h e s t o r a g e a i s l e , from overhead collector bars. Therefore, the hybrid vehicle combines the aisle transfer capability and maneuverability of narrow aisle fork trucks with the high level storage and in-aisle speed of storage-retrieval machines. 3.2 3.2.I STORAGE-RETRIEVAL MACHINES Selective Storage Systems

I{hen transaction rates and/or inventory volumes are high and sophisticated and computer-oriented operations are feasible, it is often desirable to consider reduce high cube mechanized storage and handling systems. These facilities personnel requiremenEs, increase the potential for computer-based operations, (ttnn to page 3 - 10)

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lIY]P]ICA]L ]R]EACHI T]RIUCK

Figure 3-2

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T'YP[C.A']L DCUtsN-.E R]EAC]Til 1I]RUCK SNDtrN-OADtrR.

\3 - 5 Flgure 3-3

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F" R.ONT / S]tDE]LOAD]ER. L]ttrT TIRUCK

Figure 3-4

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P AL L E T AP P L I C A T I O N

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CARRIAGE A TT A C H M E N T F O R L O N GM E R C H A N D I S E

T ' YP N C A [ , ]-D F-OU]R,.]I]B.trCT]IONA F-O]RKTR.UCK

Figure 3-5 3 - 7

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lIYPNC.N]L 1IURR.]ET' IIR,UCK

Figure 3-6

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]tD II]R.IJCK ]L lIYP][C^N FilYts]R

'-7 3 - 9

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For the latest information on lean warehousing, go to www.simsconsult.com or telephone +1-740-654-1091 and improve the land use facEor. They also tend to improve inventory control and producE security and reduce product damage. On the other hand, these sysEems are not fail-safe in terms of tine based responsiveness, and they r"q,rit" a high capital investment. The applicatio. ol complete computer control is available in almost all S/R systens. Nonetheless, there are proper applications for such devices. The fully autonated s/R nachine (tr'igure 3-g) can handle targe volumes of diverse, short lot, palletized inventory in unit loads under computer control with a minimum oi human involvement.
3.2.2 ltigh Density Storage Systems

The automated bulk storage equipment (figure 3 - 9 ) c a n h a n d l e 1 5 o r m o r e p a l lets of an itern in a slot and function in a s i m i l a r c o m p u t e r - c o n t r o l l e d n o d e for high volume operations. Few Navy supply facilities have transaction rates or inventory volumes which jusEify this t y P e o f e q u i p m e n t o n a l a b o r e c o n o m yb a s i s . In addition, in terms of rnilitary reliability in a rnobilization mode, th.se machines are not failsafe. They cannot be bypassed in the event oi breakdown, poner failure, or sabotage. Automated high cube sEorage/retrieval machines are covered in more detail in Section 9. 3.3 3.3.1 ORDER PICKING VEIIICLES Fork Truck Units

Order picking fork trucks are designed to facilitate order picking by making it easier for the opereEor to control both the truck lift a;d traveL while sel lecting orders. High lift order picking trucks are normally straddle or counterbalance tyPe fork lift trucks with operating controls on a platform located between the rnast and forks. The vehicles are generally desiined for order picking in narrold aisles and use either guide rollers and rail guidance or electronic guidance systems to eliminate the need for steering. The operator rides on Ehe plaEform and can pick frorn both sides of the aiele. order picking fork trucks are generally designed to hold a pallet on which orders are placed although units are available with longer forks to facilitate order picking Eo warehouse carts or for use in furniture operations. 3.3.2 Storage-Retrieval Units

Storage-retrieval units designed for order picking are sinilar in construction to pallet handling storage-retrieval machines. The machines consist of an upright and a fork or shuttle table assembly which moves up and down the su;The machine may be captive within the aisle it serves or may be transPort. ferable through Ehe use of a transfer car or by driving between aisles in a ^nner similar to the hybrid trucks. Storage-retrieval units can be manually controlled by an end-of-aisle operator, by a nan on-board, or be computer directed for automatic order picking. Smaller versions of storage-retrieval nachines, cor- only known as small load or nini-load systems, are designed to handle metal trays typically 18" x 36" ot 24tt x 48" and ranging in height from four to 24 inches. these systems are (tuz,n to page 3 - 13)

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T'YPNC,N]L ]L \ZED P^N]L ET NNECIilAN ]FilANDILNNG SYST'E}fi

Figure 3-8

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lTY]P]tCA]L A,IUIIOMA'.II ]ED D]E]EP tsIU]LK ST'ORAG]E SYSlT]E}fl

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For the latest information on lean warehousing, go to www.simsconsult.com or telephone +1-740-654-1091 almost always computer controlled and deliver the tray to an end-of-aisle opfor erator station order pieking or replenishment. A variation of the miniload system is the carousel. A carousel system consists of a series of These basbaskeEs or frames Eypically 24" wide, 18"-24" deep, and 84" high. kets oove horizontally around a conEinuous track. A selected basket is stopThe baskets ped at an operetor station for order picking or replenishment. can nove both clockwise and counterclockwise to rnininize cycle tine. systems are relatively Storage-retrieval expensive r*ren compared to other nethods of sEorage and order picking but provide advanEages in terms of high speed operation, narrow aistes, high storage density, and high transaction c a p a ci t y . 3.3.3 Other Vehicles

'wareof order picking vehicles typically encountered in Other ctassifications house operations include 'rwalkie'r type fork lifte, order picking, and Eow units as erell as rider type tractors. The'rwalkie" vehicles (Figure 3-10) are generally ueed when a low cottt vehicle is required for low activity operThe operator uses an end controller generally ations. connected to a short arm on the truck to control the speed and direction of truck travel. Some versione are known as trwalkie riders" snd include a small platform which permite the operator to lead the vehicle through order picking aisles and ride on the vehicle when traveling between distant locatione. guided units Tow tractor units nay be "walkies", rider, or electronically and used to pull warehouse certs in a trailer-train system. A1are generally though trector trailer-traine transpo,rtaEion functione are generaLly used for within a warehouse, the use of an operator held radio control device can be ueed to remotely control a tractor-treiler train to follow the operator during order picking operations. 3.4 3.4 . t NON-POWERED VEHICLES D o ll i e s

A dolly (Figure 3-11 ) is a snall low platform type load carrier with one or more rollers, Dollies casters, or wtreels. are sinilar to platform Srucks (3.4.2) and usually have smaller wtreels and no handle. Dollies are generally equipped with three or four wheels. Because they are hand propelled, dollies ere generally ueed for Low voLume or interrnittent moves over short distancee. They are also suited for use over They are particvarious paths and can accommodatea wide variety of loads. ularly for large or awkward shaped loads and can be custom designed to useful rnove specific loads. Their use is linited by the need for a smooth floor and manpo\ter for movemenE. Occasionally, dollies ney be moved by a fork lift truck or a small powered vehicle. 3.4.2 Hand Trucks

Iland trucks are generally available in either e tlro wtreel tilted carry o r a (tr'igure 3-I2). four Tno t*ree led or six wheeled load platform configuration hand trucks are normally designed for tilt 1s and carry operation with two wtree

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COUNTERBALANCE UCK TR

PALLET TRUCK

1IYPNCA " \M.A,N.KN V EIFil]IC]LES L ]E''

Fligure 3-10 \-

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METAL

lfYPnCA[, DOnn-n]ES

Figure 3-11

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TWO WHEEL

TY]P]ICA,.N, ]HIA,ND IIRIICKS

Figure 3-12

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For the latest information on lean warehousing, go to www.simsconsult.com or telephone +1-740-654-1091 nounted at the pivot point. The load is balanced and manually moved to its destination. Trro wtreeled hand trucks rnay be fitted for special handling tasks and are generally used for moving appliances, bales, drums, and cylinders. They are useful for low volume, light weight, and short dist.ance move{r over variable paths. They can handle a wide variety of loads and operate in a linited space. Four wheeled hand trucks are rectangular load carrying platforms designed for manual movement, usually by means of a rack or handle et one or both ends. Common variations include trucks with two swivel casters located at the corners of the platforrn or tlto large wtreels centered on Lhe sides and two smaller $heels or cesterg centered on the ends. Iland trucks with the large/snall ntreel combination tilt slightly and can be pivoted to reduce the turning spece needed to rotate the platform. Four rrheeled hand trucks can be fitted with boxes or other epecial bodies for a variety These vehicles can handle e wide variety of merchandise of tasks. and are generally ueed for low volume short distance movement of relatively light loads. 3.4.3 Seni-Live Skids

A seni-live skid (rigure 3-I3) is a platform with two wheels at one end and tlto legs at the other and is designed for uee with a lift jack. jack Ttre lift coneists of a handle with two wtreels ettached that fics into a socket ac the leg end of the skid. A seni-live skid is essentially a pallet with wtreels and legs which perrnit it to be moved easily over short distances. Seni-live skids can be used to eupplenent powered equipment and provide load maneuverability in crowded work erMovement of loade on skids is slow and they are relatively eas. hard to move over long distances 3.4.4 Trailers

(Figure 3-14) is a load carrying platform mounted on four wheels or A trailer caster{t. Trailers are sinilar to four-wheeled hand trucks but are designed Eo be towed rather than pushed by hand. Trailers are steered using tno snivel casters in front or a fifth wtreel (turntable device). S o m et r a i l e r s a r e a v a i l able in four wtreel steer configurations in n*rich the front and rear rctleels are on separate fifth nrheels and are interconnected with e linkage, causing both sets of r*reels to steer and reduce the turning radius. Trailers are available in a wide variety of configurations. Ttrey nay be hauled by tractors in trailer-traine, can be conveyed by towline or fork lift trucks, or ney be towed by wire guided automatic vehicles. A wide variety of couplers are aveilable for connecting trailers into traine. Trailers find their greatest application in high volune, long distance Eransportat.ion over varying routes and supplement fork lift truck load movement between dock and storage areas. Trailers (Figure can also be used cornpatibly with towline and order picking operations The composite couplings allow the towline cert to be used as 3-15). (tutm to page S - 21)

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SEMN.L]I\T]E SK][D
Figure 3-13

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FOUR WHEEL STEER

CASTERSTEER

1IYPNCAL TR.ANN-]ERS

Figure 3-14

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EXISTING FORK GUIOE ( T YP.)

L O C K I N GP I N F O R K G U I D EA S S E M B L Y

SUGGESTED
FORK GUIDE

TOWLNNE CART' F'CRK tsCOTS

Figure 3-15

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For the latest information on lean warehousing, go to www.simsconsult.com or telephone +1-740-654-1091 either a trailer in a tractor trailer system or as a towline cart. The illustration shows the use of fork boots to perrnit the use of the cert in oralso der picking. Ttris vereatility in the warehouse cart, wtrich can be developed through the use of various attachments and nodifications, can convert the cart into a "comon denominator" handling unit for movemenE throughout a series of handling and transportation syst,ems wiLhout any need for unloading or nanually Ttris vehicle can be used rnanually to unload highway trailhandling Ehe cargo. ers or rail cars. It can be attached to a towline or trailer train system for novement to inspection or storage operatione. It can be used as a picking rnedia for order filling being dispatched by towline or trailer to the train shipping area. It can be used manualty to load the outbound vehicles. 3.5 3.5. f CRANES Jib Cranes type lifting device mounted on a horizontal (Figure 3-15) include: attached to a mounted mast. self-eupporting floor boom

Jib cranes consist of a hoist (jib). C o m r o nc o n f i g u r a t i o n s a.

Pillar supported - Jib is nounted or floor to ceiling

b.

Mast supported - Jib is mounted on a maet top and bottom supports and pivoEs.

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supported

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c. d.

Bracket - Jib is attached to the wall or column by brackete. Walking - Walking jib cranes are mounted on heavy undercarriages r'itrich rnrly move back and forth on rails eet at floor level or at floor and ceiling level. - Interlocking jib cranes are mounted in e rnnner Interlocking sinilar to the bracket type and are designed to extend the travel of a monorail hoist by connecting the ends of adjacent jibs.

e.

Loads on jib cranes are supported by a hoisting tackle fixed at or near the end of the jib or by a trolley type hoist riding back and forth on the jib. Jib cranes can be equipped with either powered or manual hoists. Jib cranes are prinarily designed for loading and unloading carriers or aerving individual work stations in nachine shops, packing ereas, or other locations requiring heavy load lifting reach. They are also used to and linited supplement overhead traveling cranes. 3.5.2 Bridge and Gantry Cranes

\-

Bridge cranes (Figure 3-f7) are lifting devices mounted on a bridge consisting of one or two horizontal girders supported at each end by trucks riding on runways and installed at right angles on the bridge. Ttre runnays can be installed on building columns, overhead trusses, frames, or free standing columne. Bridge crenes provide three dimensional travel covering any spot within the rectangular area over which the bridge moves. Ttre end riding trucks can be either top running, in wtrich the trucks run on top of runway tracks, or bottom running, in wtrich the trucks are suspended in a lower flange the runlray of (h,un to page 3 - 24)

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JINts CRANE
Figure 3-16

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GANT'RY CR.A'.N]E
Figure 3-17

3 - 2 3

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For the latest information on lean warehousing, go to www.simsconsult.com or telephone +1-740-654-1091 trecks ' Bridge cranes are capable of three directional travel consisting of horizontal movement along the length of the runnay, horizontar movement acrosg the ltidth of the bridge, and vertical movement of the hoist. Movement of the 19tg bridge girders or runltays can be either manual or powered. powered models can be pendant or radio controlled from the floor. niiage cranes are also available with transfers to permit lifting devices to move ilto adjacent bays. Advantages of bridge cranes include no interference with work on the floor, reduced aisle sPace requirements, easy acceas to most areas within the lifting briy, and extension to areas outside tnl buitaing. Bridge cranes are generarly ueed in low to medium votume activities from iirtiog i"rg", i".ry, or awkward objects' Ttrey are generally used in machine shops, foundries, and heavy assenbly repair shops. Gantry cranes are sinilar to bridge cranes but are generally supported by legs traveling on floor mounted tracks' variations are possible in wtrich one of t h e l e g s i s r e p l a c e d b y a r u n r d a ya t t a c h e d t o a b u i l a i n g ' o i - ; ; ; ; , fixed objecr. Gantry crenes can be used both indoors and outdoors and can be pendant or redio controlled. Although the applications are similar to those for bridge cranes, gentry crenes are generally used outdoors because of the support legsl 3.6 3.5.1 PALLET HANDLING MECHANISMS General and furarfork side fork

rn pallet handling operations, there are essentially tlro meens of engaging movingpallet: forks or shuttle tables. rhe fork type unite can be !h" ther divided into either fixed, flip, or rotating forks. The fixed fork rangement is the nost cormon system and is typifally r""r oi conventional lift trucks' PantograPh (ext"ntiorr) deviceer'"""r, as thoee on reach and reach trucks, nay be included in this category.. rn any case, the basic design will operete in onry one direction relltive to the truck. 3.6.2 Turret Forks

The most conrnonly encountered systems are the turret forks and ehuttle table. The turret arrangement consists of forks mounted on a pivot, allowing them to be rotated in the aisle to eervice either side of the aisle. A comparison of technique with the shuttle rable is shown in Figure 3-rg. lhlt unlike rhe flip fork system, the turret arrangement cen be designea fo rotate the loed in the aisle, but at the exPense oi an aisle wider than that required to rotate only the enpty forks. 3.6.3 Flip Forks

The flip fork design is usually encountered in high cube storage vehicles and is mounted at a right angle to the truck. Ttre storage and retrieval occurs in a nEnner sinilar to that of the turret or shuttte truck in that all pallet novements are acconplished by a direct in or out movement of the forks. To service the opposite eide or tne aisle, the op"i"tor ".r, cause the forks to flip over and thus face the opposite direction. only enpty forks can be flipPed, so this arrangement cennot Eransfer a pallet from one side of the aisle to the other without being removed from the aisle and being physically relocated in a pickup and delivery station. (tur.n to page A _ 26)

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For the latest information on lean warehousing, go to www.simsconsult.com or telephone +1-740-654-1091 3.6.4 Shuttle Table

The shuttle table arrangement consists of a pallet load table that moves horizontally to store or retrieve a pallet on either side of the aisle. Since only linear motion is used, additional space for rotaEion is not required. Therefore, the shuttle table can directly transfer pallets from one side of the aisle to the other in less time than a turret fork system would require. The system has the disadvantage of requiring extra space under the pallet to provide access for the shuttle table. As a result, either a drive-in Lr riser tyPe of rack (Section 6) is required. Depending upon system size, height, etc., this nay require a more expensive rack system. The flip fork, turre! fork, and shuttle table systems can all handle pallet loads in aisles only slightly wider than the pallet itself. The requirements for side to side load transfer should be evaluated carefully wtren seiecting a system, since placing this requirement on a turret system will uee additional aisle space and a shuttle table rnay require more expensive rack.

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