The Great Battery Debate: Is Lead-Acid or Lithium-Ion more sustainable?
As climate change continues, environmental sustainability remains a hot topic. So, it’s no surprise that sustainability is at the forefront of battery technology advancement. But with these increased efforts to be “green” come common myths about what technology is, in fact, sustainable. And debates are on the rise about which battery system is more sustainable – traditional lead-acid or the growing lithium-ion. To make the most educated decision, top factors such as recyclability, energy efficiency, and resiliency should be considered. Recycling processes aren’t always safe First, let’s address recycling. Lead-acid battery providers claim their products are 99 percent recyclable, but the process damages the environment. Evidence shows that smelting, which is used to reclaim the lead in lead-acid batteries, harms water, soil, vegetation, wildlife, and humans. Further, smelting produces silicon dioxide and slag – a mixture of toxic metal oxides. Today, many smelting factories have been moved outside of the United States because of the harmful chemicals produced. For example, the Environmental Protection Agency (EPA) still finds samples exceeding the acceptable levels of cadmium, nickel, and lead in the Big River and its tributaries in Missouri where two smelters operated until the early 1900s. Lithium-ion batteries have a longer cycle life than lead-acid batteries. In fact, when lithium-ion batteries come to their end-of-life cycle, they are repurposed – giving them a second life. They can run on a three-step recycling program: recover, reuse and recycle. After a lithium-ion battery is recovered, it can be reused and repurposed into smaller power storage systems that include solar power and grid storage. After the second life, recycling happens when the cells are refilled and sent back to the manufacturer to build new batteries. And additionally, a lead-acid battery requires more raw material than a lithium-ion battery to produce the same amount of energy. Differences in energy efficiency matter The second sustainability consideration is differences in energy efficiency between lead-acid and lithium-ion batteries. The lead-acid battery is not fully efficient at storing energy – the higher the rate of charge or discharge, the lower the efficiency. Since lead-acid batteries only charge to 80 percent under constant current, the overall charging process is slow. These batteries become damaged when charged under high ambient temperatures or when charged incompletely. On the other hand, lithium-ion batteries charge rapidly when fully drained and can be topped off without suffering damage during brief inactivity. This allows businesses to minimize the amount of space required for charging, while keeping fewer spare batteries on hand. And more space for products leads to higher throughput. In addition, lithium-ion batteries perform consistently, delivering the same voltage at 10 percent or 100 percent. Lithium-ion batteries have a one-hour opportunity charging benefit. So, during an eight-hour shift, charging the battery during short breaks and mealtime keeps it running all day. This means only one battery is required for each piece of equipment, whereas lead-acid batteries typically have a charge, discharge, and equalize process that require three batteries per piece of equipment for a company running three shifts. Getting real about resiliency The last sustainability factor surrounds resiliency and safety of each battery type. The two types of lead-acid batteries are (1) flooded and (2) valve-regulated lead-acid (VRLA). Although flooded batteries are the least expensive, they are also the least resilient to damage. They require significant daily care and maintenance, usually from a dedicated employee. VRLA’s require less maintenance but have a short cycle life compared to their flooded counterpart, and much shorter than lithium-ion. Lithium-ion batteries are maintenance-free: no watering, equalizing, or swapping to keep them running. Therefore, there’s no risk or harm if the battery is dropped, no employee dedicated to their maintenance, and no storage needed for extra batteries. Sustainability contributes to competitiveness It’s imperative to consider how all types of sustainable power sources contribute to the future. Do your own research on the myths and facts surrounding lead-acid and lithium-ion battery recycling, energy efficiency, resiliency, and cost before deciding to stay with what you have or switching to a newer motive power source to run your fleet. You’ll gain confidence in your overall strategy to stay competitive and can determine how your choice helps the global environment. Technologies change. Environments change. A company should consider whether it, too, can or should change, not only to be more sustainable but to contribute to its bottom line. About Green Cubes Technology Green Cubes Technology is a designer and manufacturer of lithium power systems. Utilizing proven hardware and software platforms to build the most reliable lithium battery systems in the industries they serve. With over 30 years of successful designs by expert engineers, Green Cubes Technology ensures each system will exceed the safety and performance it was designed to meet. Green Cubes Technology is a global company employing teams in four global locations. For more information visit www.greencubestech.com.
Westfalia shares tips for justifying the Cost of Warehouse Automation
Storage solutions provider shares insight into the benefits, costs and return on investment of warehouse automation Westfalia Technologies, Inc. (Westfalia), a provider of logistics solutions for manufacturers and distributors since 1992, advises warehouses and distribution centers to turn toward automation to maximize efficiency and reliability of daily operations. Titled “Does it Add Up? Justifying the Cost of Your Automation Project,” Westfalia’s new white paper explores the benefits of warehouse automation and how to maximize return on investment. Westfalia suggests by using automation, warehouses can make better use of cube space and reduce overall building footprint, leading to increased productivity. Over the past few decades, warehouse automation has become crucial to the efficiency and reliability of warehouse operations across the globe. The recent rapid growth of sales in the omni-channel marketplace has significantly affected warehousing operations, causing a heightened need for adaptable systems with increased capabilities and flexibility. Today, automation can help warehouses and distribution centers operate more proactively and efficiently year-round. The benefits of warehouse automation include: Maximizing the square footage of the warehouse More work opportunities for millennials Enhanced inventory accuracy and control Higher throughput with less labor Minimized product waste Increased ROI and efficiency Dan Labell, president, Westfalia Technologies, “Our goal at Westfalia is to help growing companies expand operations and increase overall efficiency in order to meet the escalation of consumer demand. By introducing automation solutions into the warehouse, including high-density automated storage and retrieval systems (AS/RS) and warehouse execution systems (WES), manufacturers can not only meet high levels of demand, but also set themselves up for future growth.” To learn more about justifying the cost of warehouse automation, access the free Westfalia white paper here: Does it Add Up? Justifying the Cost of Your Automation Project.
How late is too late to replace equipment?
When is the optimal time to replace equipment? There are many factors to consider when making that decision, and it’s usually not an easy one to make. No wonder why so many businesses in the access and construction industries put the decision off until their equipment decides for them by way of some catastrophic failure. On one hand, businesses that do this may think they’ve gotten every bit of productivity and utilization they can from a particular asset. On the other, they may have unintentionally increased the amount of that investment. Here’s what we mean. Lurking Downtime Downtime can happen anytime. And as you’ve probably experienced, it usually happens at the worst possible time. But the probability of your equipment failing rises with each additional hour you have it in service. Not to mention, if you’re reading this, the equipment you own is probably operating in a harsh environment, like a construction site, all day. That means downtime is almost certain to happen at some point. It’s like snow on a mountainside–each flake gets you a little closer to an avalanche. But which flake will push it over the edge? And when? It could be two years, or it could be two days. In a perfect world, almost everyone would replace or recondition equipment at regular intervals, if only to reduce the chance of downtime at the worst possible time. But the real world includes money, and budgets. Fortunately, it also includes equipment financing, which gives you more choice in the matter. In fact, the right financing plan can include regular replacements in the terms, as well as provisions to help you handle any unexpected equipment failures. What’s the cost of downtime? That’s as hard to calculate considering it depends on so many factors. But it’s almost definitely greater than you think. Lost productivity, and ultimately lost revenue, certainly should figure into your thinking about equipment replacement cycles, as should considerations like cash on hand (link to Cash vs Finance blog), equipment financing, repair costs, safety, and the opportunities and challenges specific to your business. Creeping Inefficiency Just because equipment is working doesn’t mean it’s working well. Functional equipment can be inexpensive in one sense (you don’t spend money to replace it) but really expensive in another (you’re spending more time doing less and falling behind the competition in the process). As with downtime, combating inefficiency comes at a cost. But the value of staying at peak productivity is usually far greater than the cost of replacement equipment. And options like equipment financing can help a business replace equipment at the right time, instead of the time that may be otherwise dictated by cash on hand, budget pressures, and other factors. Mounting Maintenance Costs Just about all equipment needs routine maintenance. But older equipment is more likely to need extraordinary amounts of it. It’s easy to think of total cost of ownership as being a set figure, but it actually rises over time, eating into – or overtaking – any savings businesses may see from running equipment until it won’t run anymore. There’s also parts availability to consider. As equipment ages, maintenance parts become harder to source. And when you can get them, they tend to be more expensive. this is yet another factor that contributes to a rising total cost of ownership. Purchasing Pressure Replacing equipment after it breaks can cost a business more and constrict your choices. Urgent deals usually aren’t the best deals for the party that’s in a hurry. If you need it now, you won’t have the luxury of waiting for a discounted price or other incentives like a further extended warranty or free shipping. And if you’re not able to wait on an order to come in, you’ll be limited to the stock your equipment dealer or manufacturer has on hand. Since you probably won’t be buying less than you need, chances are fairly good you’ll end up with more than you need – and spend more than you need – if the ideal choice isn’t available now. Lock-in can also be a concern. Equipment can be a significant investment, and a rushed purchase can end up negatively influencing other purchases or even dictating whether or not you’ll pursue certain opportunities. Equipment purchases often cast a long shadow. So, it’s advantageous to act before you have to by using tools like financing to relieve pressure on cash, credit lines, and other resources that may be better used for other purposes. Do You Have a Proactive Equipment Replacement Strategy? For all these reasons, it’s usually best not to run essential equipment as long as possible. If you can’t do business without it, it’s just good business to replace it at regular intervals and ensure it’s there and doing all it should to help your business grow. Want to stay up to date with industry news and trends similar to this? Make sure you subscribe below to receive monthly updates from Direct Access with newly posted content, so you never miss important information.
E-commerce Distribution: How to embark on a Digital Transformation
According to the Gartner Digital Commerce Vendor Guide, 2018, “Digital commerce is a major component of a superior customer experience, with a growing ecosystem of technologies, vendors, and services.” Opportunities abound when trading partners work together to create a seamless, automated, and error-free supply chain with a focus on providing a simple, effective, and enjoyable user experience. Many companies excel at managing a large volume of digital transactions with both vendors and customers, while others have focused on the ‘online’ engagement. The fact is that both areas are critical to reaching a high level of digital maturity and the resulting benefits. In this blog, we will look at some of the key findings for wholesale distribution companies embarking on a digital transformation of their business through e-commerce distribution. Investment and cooperation A digital transformation initiative through e-commerce distribution is only possible with the full support and cooperation of finance, supply chain, and IT. The level of investment will vary by industry and company size, but it is important to keep in mind that a digital transformation is a long-term journey that will be constantly influenced by new technologies, new relationships, and unpredictable customer expectations. The continued adoption of AI and Internet of Things (IoT) technologies will greatly influence how companies do business. Think about how Amazon has used AI to anticipate the actions and needs of the customers. In fact Amazon has used AI in almost everything it does! Digital business maturity It was not long ago that most businesses regarded e-commerce only as a retail tool. In the U.S., online retail spending grew to $453.4 billion for retail purchases in 2017, representing a 16% increase over 2016. However, beyond retail, the 24-hour digital and ultra-connected lifestyle of just about everyone under 50 means that all businesses must meet the digital expectations of the modern buyer. In fact, studies show most companies invest in digital commerce to improve overall customer satisfaction. Responses to a recent Forrester1 survey suggest that companies fall into four levels of digital maturity: Skeptics: These companies have fallen behind and are just now looking at a digital transformation. Few companies fall into this level. Adopters: These companies are actively investing in skills and infrastructure in support of their digital roadmap. Collaborators: These companies are breaking down traditional silos and achieving significant gains in efficiency and customer loyalty. Differentiators: These companies are leveraging data not only to drive customer retention, but also to carry out a digital strategy that moves them toward double-digit growth. Through e-commerce distribution, distributors should aim to offer business customers the same rich experience retail buyers expect through while acknowledging and addressing the idiosyncrasies of serving a business buyer. Technology challenges Per Gartner, “Integration and interoperability of multiple digital commerce ecosystem applications continue to be a challenge.” Modernizing your business platform is a critical success factor to achieving your digital transformation through e-commerce distribution. Businesses that are locked into older legacy applications are required to deploy expensive third-party tools to allow them to integrate internally and with their trading partners. This is a particular challenge for distributors who typically buy and sell to businesses with varying levels of maturity and expectation regarding digital transactions. Furthermore, legacy systems slow the adaptation process because customization is both difficult and expensive. When it comes to business functionality, the order lifecycle should not be hampered by poorly integrated order management and warehouse management systems. For example, the poor integration of the receiving process can increase an order’s lifecycle by up to 24 hours—or worse. Furthermore, customers want to track the progress of their orders and deliveries. Internally, customer service representatives need access to the information required to answer questions regarding stock availability, available to promise, and the status of the customer’s order. Regarding digital commerce platforms, the good news is there are many options available to companies that wish to grow their business within both B2B and B2C markets. The reality is that not all companies can justify the large initial capital investment required to deploy a mature, flexible e-commerce distribution application with perpetual licenses and annual support fees. There are many vendors that offer SaaS solutions that are owned and managed by the vendor. However, the SaaS approach may lead to more of a ‘me-too’ deployment instead of giving customers an innovative and superior user experience. Another option is open source solutions. Some of these are designed to support shopping cart-only options, while others offer a complete business commerce platform. Deployment of an open source solution should not be attempted without the right skill set. In addition, the cash saved on the front end may be swallowed up by the cost of the IT effort required to deploy and maintain these applications. Finally, marketplace platforms such as Amazon, eBay, and Alibaba have enabled the growth of small and large businesses—but at a cost. One must consider the intensity of competition on these sites, and of course, marketplace fees. Building trust Businesses have the responsibility of securing their business data, particularly information relating to their customers. A lack of trust resulting from a data breach can severely impact revenue and damage a company’s brand. According to Forrester “Over 80% of high performers report that a security breach would have a catastrophic impact on their business. The majority also feel that securing revenue from attack hinges on securing customer data, not company data.” Your digital transformation roadmap must include strategies for securing all of your data. E-Commerce distribution—at a profit A successful deployment of e-commerce distribution not only provides a superior user experience, but it also delivers product as quickly as possible at the lowest possible cost. Distributors, as aggregators of product over large geographical areas, are uniquely positioned to do just that. The missing piece for many distributors is the intelligent routing of orders. Distributed order management solutions provide a centralized view of all orders and determine how to ship product to customers based on an easily adaptable set of business rules. Complex order fulfillment leads to errors, longer lead times, and margin erosion. Creating an outstanding relationship with your
Cincinnati Crane and Hoist customer story
White Paper: Innovative overhead crane manufacturer uses state-of-the-art wireless remote to grow business, increase productivity and improve operator safety supplied by Schneider Electric. Click here for the White Paper.
Benefits of expert service for Industrial and Commercial Scales
Protect against high cost of inaccuracy and unscheduled downtime When a product is bought and sold by weight, the scale acts as a cash register. Scale uptime and accuracy is absolutely critical for performing transactions necessary for remaining in business. Over time, losing even a few pennies per transaction due to an inaccurate scale can add up to losses into the hundreds, thousands, or even hundreds of thousands of dollars. This holds true whether the products are large or small and whether the scale is a small counting scale or a large hopper, truck, or railroad track scale. Regularly scheduled scale service by a reputable scale service company protects against the high cost of inaccuracy and unscheduled downtime. Importance of scales to production Scales are an integral part of production, whether the product is raw materials or finished goods. A scale breakdown can potentially shut down an entire production line, costing a manufacturer an ever-increasing amount of money until that line is up again. Businesses selling product based on weight must usually have the scale tested by the local weights and measures inspector. Should that agency determine that the scale is not within tolerance, the inspector may lock out or close the scale – possibly closing the business until the scale can be brought back into tolerance. Expert scale service will ensure maximum accuracy while preventing costly downtime A scale is a precision measuring device, built with delicate high precision components. It may represent a huge investment – and one that is often placed in a harsh environment. Over time, especially in heavy capacity applications, wear and tear of key components will degrade the accuracy of the scale. A scale service expert will work to understand the unique weighing applications and service requirements of their customers and help to determine a service program and frequency that will best service them to maintain accuracy and uptime. Expert service does not simply mean placing a weight and a sticker on a scale when on site for a preventative maintenance service or an emergency repair. Expert service means taking the time to become familiar with a customer’s unique weighing application and service requirements and providing trained technicians who will take the time to inspect the critical components. It also involves taking the time to check for dirt and debris that will impede weighing accuracy as well as reviewing major component wear or damage to ensure the scale is in top operating condition. Expert service includes test and calibration with certified and traceable test weights; compliance with National Institute of Standards and Technology (NIST) Handbook 44 standards; and provision of written reports that will indicate section testing and overall calibration – with as-found and as-left readings recorded. An added value that an expert service company can provide is a secure online portal that allows the end user to access, view, and print reports any time. Costs can add up quickly when an owner scrimps on scale service. Simply placing a weight and a sticker on a scale can end up costing more than expert scale service. Take the example of an owner of a truck scale with a 300 pound (lb.) error. If that owner is selling product across the scale for $0.05 per pound and sells 20 truckloads per day, that would be 100 truckloads per week and 5200 truckloads per year. The error translates to a loss of $15 per truckload, $300 per day, and $1500 per week – that is $78,000 per year! Costly breakdowns can be prevented with expert scale service. A scale failure can shut down production of an entire operation. Many of these costly breakdowns can be avoided with proper preventative maintenance inspections that identify potential failures that can be resolved long before they become a costly problem. Loss of production is not always caused by a scale breakdown. Operation can be shut down if a scale does not pass weights and measures inspection. In addition to the loss of revenue from production stoppage, a company may also face fines for scale inaccuracy. With proper service a business owner can avoid the additional and unexpected costs due to inaccuracy and component failure. Environmental, regulatory, and economic factors determine the need for scale service Most truck scales are installed outdoors, where they are exposed to the elements year round. In additional to the daily wear and tear from fully loaded trucks rolling across a scale, truck scales are exposed to rain, snow, ice, dirt, debris from surroundings, and even wildlife. All of these will affect the operation of the scale, creating the need for regularly scheduled service. Scales used in commerce where product is sold based on weight are subject to local weights and measures authorities. Most weights and measures jurisdictions require annual scale testing and certification. Regularly scheduled testing and calibrations ensure that the local weights and measure entity will not take the scale out of service or levy a fine due to inaccuracy. Safety and Department of Transportation (DOT) regulations also factor in to how service is offered. An expert service company will maintain excellent safety ratings with thorough job planning, providing safety training, use of proper personal protection equipment (PPE), and job safety assessments. These factors, as well as mandatory DOT electronic logging device (ELD) regulations, greatly influence how certified weights are transported in commercial vehicles. Benefits of expert scale service There are several benefits to expert scale service, and each results in cost saving. Expert service will: Ensure accuracy, which will prevent loss caused by unknowingly giving away product. Ensure that a scale is dependable and far less likely to suffer a crippling breakdown in the middle of a production run. Extend the life of a scale. A truck scale is a substantial investment. Expert scale service means not only checking for accuracy but also inspecting and addressing the potential problems before they become catastrophic failures. With expert scale service, some older scales can be overhauled and returned to their original condition, thereby extending
What lighting does your lift truck need?
Machinery is involved in more than 30% of the most serious industrial accidents. Visibility plays an important role in this. Also for you, as a forklift driver, it is important to be sufficiently visible on the shop floor. So don’t just make sure that you have a clear view of your surroundings, but also that nobody loses sight of the vehicles in and around your company. In function of the safety and visibility on the shop floor, we provide you with a number of guidelines to optimize the lighting of your forklift truck. Which work lights are mandatory? Legally speaking, your forklift truck must be equipped with a lighting system that sufficiently guarantees the safety of the employees during the work to be carried out. The most obvious solution is to mount LED or halogen lights on the fork carriage or overhead guard. This way, you have an amply illuminated zone in front of the forklift truck. Good front and rear lights make you easily visible, even in dark areas such as warehouses. Can you use your lift truck on public roads? Yes, but you have to observe the traffic regulations with your forklift truck. There are also a number of other conditions attached. First of all, a number plate with number plate lighting is mandatory. Furthermore, your forklift truck must be equipped with: Both dimmed headlights and parking lights at the front Indicators at the front and rear Hazard warning lights Red reflective triangle at the rear Two rear lights Two brake lights At least two reflectors Finally, all lights must have an E-marking in order to be allowed on public roads. Make your truck even safer with projection warning lights The standard equipment for your forklift truck ensures that you as a driver can clearly see where you are driving. Meanwhile, various projection warning lights have been launched onto the market that also warn pedestrians for an oncoming machine. Blue spot warning lights By means of a red or blue spot on the floor in front of or behind the forklift truck, everyone can see the machine coming before you come around the corner. The blue spot is a safety light that you can easily mount on top of the machine. Red zone light With a light that marks out a red zone along the machine, you can demarcate a safe distance for everyone in the workshop. This light can also be mounted in combination with the blue spot. By combining these warning lights, you create a safe zone in the front, back and on the sides. Do you wish to know more about lights? Are you curious about our range? Feel free to download our catalog. Do you have any questions afterwards? Please contact TVH by clicking here. white
Budweiser Budvar replaces RFID-Powered Forklift Tracking with SEWIO RTLS
Achieves 99% of system uptime and cut down maintenance costs The Budweiser Budvar Brewery was using a passive RFID solution to minimize human error while operating thousands of pallets with hundreds of varieties of beers using forklifts equipped with an RFID antenna at their chassis and RFID tags located at each of the tracked pallet positions. Due to the easily desynchronization or even damage of antennas the maintenance cost grew rapidly and the system uptime was only 80%. In order to retain the process of minimizing human errors in logistics but crucially lower the maintenance costs and increase the system uptime, Budweiser Budvar decided to replace the RFID-built system with Sewio RTLS powered by ultra-wideband technology using Decawave chip. The implementation was provided by ICZ Group, a Gold partner of Sewio. With the newly implemented system, antennas are placed high above the actual traffic and the reliability of the system itself has resulted in 99% of system uptime. The newly acquired insights into the distance traveled and the utilization of each forklift, together with heatmaps and spaghetti diagrams, have allowed Budweiser to better utilize the current warehouse, virtually growing it by 19%. “While the initial cost for RFID versus UWB is almost identical, UWB undoubtedly outperforms RFID thanks to lower maintenance costs, lower risk of damage and higher accessibility and scalability of the system”, said Pavel Pánek, Head of Logistics at Budweiser Budvar. “In many uses cases, we see RFID and UWB RTLS complement each other well when integrated into a single solution. If our customer needs precise true location data provided by a scalable system with a low maintenance cost, UWB is then the right first and only technology to choose”, commented Milan Šimek, CEO of Sewio Networks. “At Decawave our goal is to make micro-location technology available to the masses by providing chips with state of the art performance at an affordable price. We are delighted to see partners like Sewio embrace the same philosophy and deliver RTLS systems that are cost competitive while delivering superior performance and capabilities to end customers” said Mickael Viot VP Marketing at Decawave. Please read the full case study here https://www.sewio.net/customer-projects/budweiser-budvar/
MSM Solutions improves logistics and warehousing at Randa’s Fulfillment Center
MSM Solutions, a global provider of RFID and barcode solutions, implemented an RFID tracking solution for real-time inventory management at the world’s largest men’s accessory company, Randa, in their Reno Nevada Fulfillment Center. “The challenges that Randa faced are the same problems that many businesses face; accurately identifying where stuff is and how much they have. Utilizing RFID and our PortalTrack software we were able to bring real-time visibility to the Randa Fulfillment Center. The results enabled Randa to easily and accurately identify inventory locations and counts; which in turn lowered labor and operating costs, increased customer satisfaction and enabled real-time decision making.” Brett Wilkerson, RFID Business Development, MSM Solutions. MSM Solutions has been providing RFID and barcode technology for 37 years and is a pioneer in GS1 Electronic Product Code (EPC) Serialization. In 2012 Randa requested assistance from MSM Solutions to meet RFID compliance tagging for select retailers. In 2016, Randa Logistics approached MSM Solutions with an idea on expanding the use of RFID at one of their state-of-the-art 525,000 square foot Multi Fulfillment Centers in Reno, Nevada. The goal of the project was to identify, track, count, and manage pallet-level shipments headed to retail stores throughout the United States. Storage space was limited due to tens of millions of product units moving annually. MSM Solutions tailored its Portal Track Software solution to provide real-time results. The reporting features provided Randa with real-time visibility to the present location of any pallet in the fulfillment center, Randa Logistics can login to any web-enabled device and see all available pallets for shipping by customer PO and Retailer with the added functionality to search and sort by other variable data. MSM Solutions also provided a mapping feature that is an exact replica of the 525,000 square foot Randa fulfillment center that will pinpoint any pallet within a zone or show all available pallets within a selected zone. “We have replicated this same model with other customers and see a continual climb in the number of requests for similar applications. As RFID becomes more and more mainstream, we will see many more customers adopt this approach and leverage the power of RFID to Identify – Track- Count and Manage inventory,” Brett Wilkerson, RFID Business Development, MSM Solutions. “The real-time visibility and reporting that PortalTrack delivered has allowed us to make better and more timely decisions. Knowing exact counts and the exact locations of items in a facility this size has eliminated wasted labor costs searching for items, prevented shipment delays and helped us avoid chargebacks,” stated Randy Kennedy, Chief Logistics Officer at Randa Logistics. MSM Solutions and Randa documented the problems and solution in a case study, RFID Enables Real-Time Visibility at Randa Fulfillment Center, available for download.
Dematic white paper provides update on mobile automation
Dematic, a global supplier of integrated automated technology, software and services to optimize the supply chain, has released a new white paper that provides a technology update regarding Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs). The white paper, Automated Guided Vehicles (AGVs) vs. Autonomous Mobile Robots (AMRs): Debunking the Myths, describes and clarifies the capabilities of both technologies. Automated Guided Vehicles (AGVs) have long been recognized as the efficient mobile automation solution to move raw materials, work-in-process materials and finished goods in manufacturing operations as well as supporting order fulfillment functions in warehouses and distribution centers. Recently, a new variation of mobile automation has appeared: Autonomous Mobile Robot (AMR). The producers of AMRs have defined this technology as a completely new category of automation. The reality is that AMRs are a subset of AGVs focused on a specific navigation technology, physical size/payload capabilities, environment, and routing abilities. “Vision-based guidance, dynamic routing, and 3-D sensors are some of the design elements and attributes common to both AMR’s and AGVs” says Tom Kaminski, Vice President Mobile Automation with Dematic. “This white paper describes the universal attributes of Automated Guided Vehicles and Autonomous Mobile Robots, and how both these technologies enhance intra-logistics effectiveness.” To download the whitepaper, visit: https://info.dematic.com/e/126491/ure-white-papers-agvs-vs-amrs-/5rx5k2/302384193
Digitizing Global Trade with Maersk and IBM
A global trade platform using blockchain technology aimed at improving the cost of transportation, lack of visibility and inefficiencies with paper-based processes
US & China: Tariff Impact report
In this third tariff white paper, analysts from the Freedonia Group contemplate the current realities and future possibilities of trade relations between the US and China, summarizing the potential impact of proposed and enacted tariffs on affected industries in both countries. The Freedonia Group has a long history of analyzing US and global industries as well as trends in international trade. In addition, corporate researchers in Freedonia’s Beijing office conducted interviews with Chinese market leaders to provide a ground-level view of how impacted Chinese companies are responding to the US actions.
Determining Crane Inspection frequency
Operational productivity is maximized, total repair costs are reduced, and safety of your equipment is optimized when you have implemented the optimum inspection and maintenance frequency for your overhead cranes and hoists. The big question is: How do I know what is the Optimal Frequency? Worker safety is an obvious priority for every business, so the minimum frequency of inspections must ensure that equipment conditions are monitored frequent enough to ensure safety. If your cranes are always safe, you also reduce employer liability and potential OSHA compliance issues – beyond worker safety. The priority of equipment operational cost and productivity vary in importance from one business to another. Lost production time from out of service crane equipment can cost some businesses tens of thousands of dollars per hour; while for others, it is only a minor inconvenience. Inspections that identify deficiencies that allow for planned repairs and subsequently reduce or eliminate crane-related unplanned downtime can be great investments in a “production critical“ business. A great crane and hoist inspection program starts with well trained and qualified inspectors taking enough time to thoroughly inspect all the equipment components that could be deficient and might contribute to a future safety incident or unplanned breakdown. Great Inspectors are not enough; you have to implement a schedule of OSHA “Frequent” and “Periodic” inspection that is frequent enough to hopefully catch problems before they lead to a safety or production incident. So it is critical to understand the equipment in your facility and the factors that contribute to the need for more or less frequent inspections. Those factors are: The propensity of the equipment to break: This factor is heavily influenced by the age, maintenance history, and condition of the equipment. The use of grabs or lifters. These cranes are always under load and continual wear. The intensity of use: Equipment used continuously over three shifts each day will see far greater wear and tear. Cranes lifting at or near capacity are working harder. The environment: Equipment in a hostile environment including severe heat, moisture, cold, dust, or chemical exposure will see added stress and deterioration of structural, mechanical and electrical components. Operator training: Poorly trained operators will likely cause increased stress on the equipment by jogging the motion and violating conservative operating practices. One of the best methods to gauge the effectiveness of crane inspection frequency is to routinely examine the number and severity of safety and operational deficiencies that crop up in the time frame from the last “Periodic” inspection to the most recent. If you are performing “Periodic” inspections every 3 months and you have 1 or fewer safety or repair deficiencies then your current program is likely sufficient. If your cranes each routinely have more than 2 or more within a given time frame, then we would recommend decreasing the “Periodic” inspection period so that you have no more than an average of one newly found serious deficiency in the interim period. Review the service manuals for the crane and hoist; note both the recommended service and maintenance intervals. Never increase your intervals beyond that of the manufacturer’s requirement for both safety and liability sake. OSHA designated “Periodic” inspections (Monthly to Annual) are very thorough and should catch all of the visible deficiencies. OSHA designated “Frequent” inspection (Weekly to Monthly) are visual and operational. These are partial inspections designed to catch really serious issues that might crop up in between the much more comprehensive “Periodic” inspections. In a Periodic Inspection, the Inspector must access the equipment using a lift or the crane walkway to review the condition of mechanical, electrical and structural elements of the crane and hoist. Control panels are opened; mechanical components such as drums, wheels, sheaves, and couplings are reviewed for wear; breaks are checked for wear and adjustment, and gearboxes checked for oil level. The great thing about proper crane and hoist inspections is that the cost is relatively small in comparison to the benefits of increased safety and the reduction of unplanned downtime costs. So more is better. We find businesses that perform “Periodic” inspections on a monthly frequency have the fewest safety problems and breakdowns.
Safety tips for the overhead crane operation
Safety Tips for Overhead Crane Operation 1) Before use, ensure the crane is suitable for the planned hoisting task. Confirm it has appropriate travel, lift, and capacity. 2) Visually and physically inspect the crane before use. Check for damage, wear, and proper operation of all functions. 3) Confirm the load weight. Check the capacity of all equipment including the hardware, rope, and slings. Do not exceed these capacities. 4) Select the right sling for each lift. Inspect slings and other rigging hardware before use for wear, stretch, or other damage. Do not use damaged or defective slings. Use softeners around sharp corners. Do not splice broken slings. 5) When communicating with a crane operator, use clear agreed-upon signals. Except for the stop signal, the crane operator should follow instructions from only one person – a designated signaler. Where a wired or remote controller is used, the operator should become familiar with all of its functions before lifting the load. 6) Warn all people in the load lift area before starting the lift. Ensure that the path of the load is clear of persons and obstructions. Do not lift loads over anyone. Center the crane hoist over the load before hoisting to prevent swinging of the load. 7) Slide the sling fully onto the hoisting hook and ensure the safety latch is closed. Do not load the hook tip or hammer a sling into place. 8) Secure unused sling legs. Do not drag slings or leave loose materials on a load being hoisted. 9) Keep hands and fingers from being trapped when slack is taken out of a sling. Step away before the lift is started. 10) Move the load and controls smoothly. Minimize load swing. 11) Walk ahead of the load during travel and warn people to keep clear. Use a tagline to prevent rotation or other uncontrolled motion. Raise the load only as high as necessary to clear objects. Do not ride on the hook or load. 12) Set loads down on blocking, never directly on a sling. Do not pull or push loads out from under the hoist. 13) Do not leave the load (or the crane) unattended while the load is suspended. 14) Where crane operation by other personnel must be restricted, employ lockout and tagging procedures. 15) Store slings off the floor in a clean, dry location on hooks or racks. Do not leave slings, accessories, or blocking lying on the floor.
Explosion proof and spark resistance
There is some confusion regarding explosion proof and spark resistance. The following article explains the difference and gives some information on how to specify the classification of the application. EXPLOSION PROOF The “Explosion Proof” term defines the electrical enclosures, controls, motors and wiring requirements required to contain any spark or arcing from penetrating the confines of the enclosure and potentially igniting the combustible material present in the atmosphere. SPARK RESISTANT “Spark Resistant” refers to the mechanical and structural elements of the hoist or crane that could create a spark based upon usage. Friction between certain materials can cause sparks sufficient enough to ignite flammable gas or dust. A cigarette lighter or an antique flintlock musket are familiar examples of this. The type and concentration/dilution of gases in an area is one element that affects potential ignition from a mechanically generated source, but other key factors could include -The type materials making contact -The speed/pressure with which the materials come into contact -Corrosion on one or more of the contacting surfaces -Lubrication Contact between steel surfaces can create sparks. Steel is commonly used in most hoists and cranes for load-bearing components such as hooks, lower blocks, load chain and trolley wheels, and therefore may not be suitable for some hazardous environments. In the U.S., NFPA 70, part of the National Electric Code (NEC), addresses the design and installation of electrical conductors and equipment in hazardous areas but does not specifically provide guidelines for mechanical equipment used in these same hazardous locations. APPLICATION When an application requires a determination of an explosion proof Class, Group and Condition most hoist and crane suppliers and manufacturers require that the purchaser defines the hazard and the NEC classification. The requirement for spark resistance features also needs to be determined by the purchaser. Therefore, we recommend that purchasers thoroughly research the combustible sources in the operating environment and engage the professional opinion of a qualified engineer to determine the proper Explosion Proof Classification as well as Spark Resistance features. Explosion proof and spark resistant features do not come cheap. Depending on the NEC classification, special motors, explosion proof enclosures, control pendants and safety limits may be required; sometimes doubling the price of the equipment. The capacity rating of the equipment can be reduced when stainless wire rope or chain is required for spark resistance since it is not as strong as the same parts in steel. Technology has helped in some classifications using intrinsically safe relays that preclude the need for very expensive, large and heavy explosion-proof components. Options to save money on spark resistant features include the use of copper plated hooks in lieu of very expensive solid bronze hooks. Contact a CRANE 1 application expert who can walk you through the requirements and ensure that you receive equipment suited to your application. NEC Explosion Proof Classifications for Equipment (Class, Group & Division) Class Class I – Locations: Are those in which flammable gases or vapors are or may be present in the air in quantities sufficient to produce explosive or ignitable mixtures. Class II – Locations: Are those in which are hazardous due to the presence of combustible dust. Class III – Locations: Are those which are hazardous due to the presence of easily ignitable fibers or flyings, but in which such fibers or flyings are not likely to be in suspension in the air in quantities to produce ignitable mixtures. Group Groups for Class I (above) Group A – Atmospheres containing acetylene. Group B – Atmospheres containing hydrogen, or gases (or vapors) of equivalent hazard, such as manufactured gas. Group C – Atmospheres containing ethyl-ether vapors, ethylene or cyclo propane. Group D – Atmospheres containing gasoline, hezane, naptha, benzine, butane, alcohol, acetone, benzol, lacquer solvent vapors, or natural gas. Groups for Class II (above) Group E – Atmospheres containing metal dust, including aluminum, magnesium and their commercial alloys and other metals of similarly hazardous characteristics. Group F – Atmospheres containing carbon black, coal, or coke dust. Group G – Atmospheres containing flour, starch, or grain dust. Division Division I – Locations in which hazardous concentrations in the air exist continuously, intermittently, or periodically under normal operating conditions. Division II – Locations in which hazardous concentrations are handled, processed, or used but are normally within closed containers or closed systems from which they can escape one in case of accidental rupture or breakdown.
ASG Services whitepaper on the complexities involved before embarking on a major marking project.
Using the correct indoor floor striping and marking scheme is an integral part of any warehouse or distribution center setting. Choosing the best method, deciding on the layout and finding time to deliver it can become a significant project. Read ASG Services white paper on internal line striping, possibly the most comprehensive document written for users of industrial floor markings. We created it to help readers learn, question and understand the complexities involved before embarking on a major project. Click here to view the white paper
Alpine Accumulation defers product up to 4 minutes of off-line production
Reducing downtime
BEUMER Group is shaping digital transformation in intralogistics:
Transformation is inevitable
BEUMER Group: Technical Report – Cement: The material that holds the world together
BEUMER Group supplies tailor-made solutions designed to make the production of cement more energy-efficient and eco-friendly: The material that holds the world together Cement is the most commonly used building material worldwide and is continuously growing. Cement manufacturers are however faced with challenges: complying with ever stricter environmental regulations, in an industry with some of the highest carbon dioxide emissions. They are also faced with permanently increasing cost pressures due to excess capacities, especially from China. Many countries therefore import the material, instead of producing it. BEUMER Group supports cement manufacturers with systems and machines that are adapted to the market, increasing the efficiency of their systems and their competitiveness. As the saying goes in the building industry: “Somewhere someone is always building something”. Whether it is in North America, Asia or Africa: large infrastructure projects require more and more material for buildings, streets, airports, bridges or dams. Since 1990, global cement production has almost quadrupled. About 4.17 million tons were produced worldwide in 2016. This growth is mainly coming from the development of the Asian markets, especially China. Despite growing cement sales, cement manufacturers worldwide face production overcapacities that have been built up during recent years especially in China. This decreases global cement and clinker prices. Due to these overcapacities, some countries focused more on the export of cement and clinker, an intermediate product when producing cement. At the same time, an increasing number of countries decide to import cement or clinker, instead of producing it domestically. In 2016, more than 150 countries imported cement and clinker. One of these countries is Australia. Brisbane for example, the metropolis on the Pacific coast, is one of the fastest growing cities on the continent. Its population of about 2 million inhabitants is expected to double by 2056. Construction sites all over the city centre are witness to this progress. Skyscrapers are springing like mushrooms. Due to their strict environmental regulations and price pressures, Australia imports an increasing part of their demand for cement and especially clinker. The clinker is imported and then ground down to cement in Australia. The imported materials are coming from multiple countries including Indonesia, China and Vietnam. The cement and clinker imports are increasingly replacing the local production. In 2016, the utilisation of the domestic cement production capacities was only at around 57 percent. Reduce environmental impacts, increase energy efficiency When producing cement large quantities of carbon dioxide is emitted worldwide. These emissions occur during various processes, but the majority comes from emitting the CO2 from the limestone used to produce cement clinker. Depending on the processes used, the carbon dioxide emissions from producing cement are at 0.6 – 0.99 t of CO2 per ton of cement. The CO2 emissions from producing cement are estimated to account for seven to eight percent of the overall global carbon dioxide emissions. Manufacturers can reduce these large quantities for example by partially substituting the cement clinker with alternative materials such as fly ash, clay or granulated blast-furnace slag. Another approach to sustainably reduce greenhouse gas emissions and production costs is to increase the use of alternative fuels for the cement production. The alternative fuels are used as sources of energy instead of fossil fuels like coal and gas. Besides liquid materials like waste oil or solvents, the majority of the solid alternative fuels are composed of municipal and industrial waste, such as plastic, paper, composite material or textile mixes. Whole or shredded waste tyres are also used and made up 6 % of the alternative fuels used in Germany for the production of cement in 2016. The calorific value of the rubber from waste tyres is comparable to that from hard coal, and the iron from the reinforcement can be incorporated mineralogically into the cement. This minimises the addition of ferrous corrective substances. Systems adapted to the production As a system supplier, BEUMER Group develops tailor-made solutions perfectly adapted to meet cement plant requirements: conveying systems such as troughed belt conveyors and pipe conveyors, different bucket elevator types and clinker transport systems, loading systems and complete packaging lines. BEUMER Group provides these solutions throughout the entire material flow chain from unloading the delivery vehicle to storing, taking samples, conveying and control feeding solid alternative fuels. BEUMER Group also provides fully automated systems that can control feed, singulate and convey large and heavy tyres to the inlet of the rotary kiln. BEUMER Group provides innovative intralogistic solutions to international cement companies who are looking for sustainable and cost-efficient ways to modernise their plants. Aalborg Portland A/S relies on these solutions for example. BEUMER Group provided a complete solution so the cement manufacturer can recover energy from different types of waste at its plant in Denmark. Different types of alternative fuels are used in the calciner and in the main burner. These fuels are made of varying compositions and are efficiently stored, conveyed and fed. The customer received all equipment from one source, thus having only one contact. The oven-ready alternative fuels are delivered in moving-floor trailers. They are unloaded and then temporarily stored at the receiving station. Both lines receive the transported material from the storehouse via the moving floors that have been modernised by BEUMER Group. To enable the transport of the pre-processed fuels from the storehouse to the calciner and to the main burner, BEUMER Group supplied and installed one Pipe Conveyor as the heart of this system. Using the Pipe Conveyor to transport the fuels is quiet and low-maintenance; and the enclosed system is also emission-free and energy-efficient. The enclosed construction prevents material from falling and dust and odours from escaping into the environment. With an ability to navigate curves, the Pipe Conveyor requires considerably less transfer points compared to other belt conveyors. This allows for substantial capital cost savings for the customer and BEUMER Group can customise the system to the individual routing. Transport – low on energy and environmentally friendly The BEUMER Group belt conveyors, Pipe Conveyors and open troughed belt conveyors, are particularly suited for
Westfalia advocates automation in modern bakeries
Storage solutions provider shares the benefits of automation in fresh and frozen bakeries for space savings, cost reductions and the elimination of labor risks