Tag: fulfillment

Using CartCaddy Products to Meet Customer Requirements

In our last post we talked about automation and how it is changing the face of the warehousing and distribution industries (see our Aug. 4 post). Automation allows businesses to handle greater volumes in shorter time periods. However, a major challenge in automating operations is the accommodation of unique customer requirements. Obtaining a customer’s business can depend upon your ability to meet their unique requirements. Doing so while maintaining a cost-effective operation can require both ingenuity and skillful management of material handling resources.

Tom Kozenski, VP of product strategy for optimization firm RedPrairie, suggested in a July 2008 Modern Materials Handling article that there are two ways to handle customer requirements: increase labor or engineer them into the normal workflow. “The first brings your operations to a grinding halt,” Kozenski said, citing the extreme cost. “The second allows you to differentiate your business from the competition.”

One way of engineering customer requirements into the workflow is to coordinate the delivery of components or raw materials to the production or assembly line with their use, Kozenski noted. Delivering materials to the assembly line in the same sequence that they will be used increases efficiency and production and, thereby, cost effectiveness. A combination of powered CartCaddies and pushers allows for maximum customization of this process.

On an assembly or production line, electric CartCaddy power tugs can be used to push or pull carts loaded with customer’s specific components or raw materials. Carts can be preloaded and delivered to the line in sequence. In a vehicle assembly plant, for example, CartCaddy power tugs can be used to deliver windows, doors and other components to the appropriate point on the assembly line for sequenced installation. In a fulfillment operation, batched orders can be carted and delivered for sequenced processing. Highly maneuverable, ergonomically designed CartCaddy products maximize the load a worker can move safely, thereby limiting the number of workers involved in material delivery.

The CartCaddy electric tug or CarCaddy vehicle pusher can then move carts, equipment or vehicles from station to station down the line. CartCaddy products are available to move equipment across the floor on wheeled tugs or on a rail. 

Tips to Improve Warehouse and Distribution Productivity

There are three key areas to consider in improving productivity at your warehouse, distribution facility or fulfillment center:

  1. Information flow must match physical flow. When the flow of information matches the physical flow of goods, inventories can be better managed and storage, pick-and-pack and retrieval operations can be streamlined, increasing productivity. It is important to realize that optimal inventory does not necessarily mean minimal inventory. To efficiently manage inventory and the flow of goods, look beyond weekly order statistics. Today’s global market demands consideration of complex logistics. If goods must be shipped from distant or multiple locations, maintaining a higher inventory of certain products can enable faster and more efficient customer response. Gathering maximum information about each specific facet of your operation allows you to discern customer and supplier patterns and the interrelationship of the many logistical factors that connect them. Developing a thorough understanding of “the big picture,” puts you in position to more effectively and efficiently direct the flow of goods through your facility.
  2. Know and improve your total operation first. Before implementing new technology, particularly before engaging in the requisite evaluation that precedes a major change in your operation, make certain you have a thorough understanding of every aspect of your present operation. Current processes should be honed and improved to maximum efficiency and productivity before embarking on the time, expense and training involved to implement new technology. A thorough understanding of your total operation will enable you to make optimal use of current processes and pinpoint areas that can best profit most from new technology.
  3. Automate where possible. As labor becomes more expensive and laborers become harder to find, automation is the key to increasing productivity. With the Baby Boomer generation reaching retirement age, the traditional U.S. workforce is beginning to shrink. There are fewer people available to replace the retiring workforce, and fewer young people are seeking jobs in warehousing, distribution and fulfillment. A smaller available workforce will be in a position to demand higher wages. Increased automation and, where automation is not possible, the use of equipment that allows a single worker to accomplish more tasks in less time can decrease necessary workforce and labor costs while increasing efficiency and productivity.

Plenty of Jobs Available in Material Handling Fields

With the economy down and unemployment up, jobs are a hot topic this election. As industry starts to feel the economic pinch, plants are closing, workers are being laid off and some companies are facing bankruptcy. But there are jobs aplenty in the material handling industry and the associated industries of logistics, fulfillment and warehousing.

There’s a severe shortage of qualified industrial workers in America, particularly in material handling fields, that holds promise for job-seekers. The material handling industry is expected to be “50% short in terms of employees needed by 2010,” said Virginia Wheeler, executive director of the Material Handling Industry of America’s (MHIA) Education Foundation. The growing worker shortfall guarantees job security well into the next decade for people going into material handling jobs in warehouses, fulfillment centers, logistics operations, and factories.

“Our industry is begging for people,” said Dan Quinn, MHIA VP for education. He feels America’s high schools are undercutting the value of the trade jobs that built and continue to build America. “A lot of schools measure themselves on the percentage of students who go on to college,” Quinn criticized. “Schools should embrace the concept that non-college-bound students are still valuable contributors to the economy and society.”

The reality is that many high school students are not interested in pursuing a college education for a wide variety of reasons. Many simply prefer hands-on, physical work to sitting at a desk. Many are anxious to get out on their own and lack the interest in four more years of schooling. Many do not have the financial resources to consider college but must provide for themselves immediately after high school graduation. As the recession deepens, finances are expected to play an increasing role in education/work decisions. Some high school juniors and seniors, like Alaska Governor Sarah Palin’s future son-in-law, have already been forced to drop out of school to help support their families. Some employers are offering their employees the opportunity to complete their high school education through GED programs.

It’s unfortunate that many high school guidance counselors are so focused on college that they ignore the positive opportunities available in material handling industries. Raising awareness of job opportunities is one of the primary challenges facing the material handling industry, said Alan Howie, author of Fundamentals of Warehousing and Distribution. “. . . the essential problem is we have to get the message out there that . . . work in the material handling industry is much more than a manual labor job. It’s a career in a high-tech industry. Our challenge is to build awareness of all of this in the schools and colleges.”

How DJ Products Can Help You Be a Survivor

As we’ve said in this space before, it’s going to take a firm hand on expenses, the guts to embrace innovative ideas and products, and the flexibility to act quickly when opportunities present themselves to survive the current recession.  DJ Products’ ergonomically-engineered carts, tugs and movers can help you get the jump on the competition and position your business to move boldly — and successfully — into the future.

Cost effectiveness, worker safety, healthcare issues, energy and environmental concerns, immigration and a changing workforce — these are among the most powerful issues that confront businesses owners today. Customers, workers, the public and the government will all be watching how we address these issues in the course of business. It’s no longer enough to produce a fine product. Today, we’re also graded on how we produce that product and the cost or benefit to our workers and the environment, not just our customers. Government oversight and a watchful press have added a few links to the food chain.

Here’s how DJ Products’ ergonomically-designed carts, tugs and movers can help you successfully meet these challenges:

  • Cost effectiveness is key when every penny counts. When DJ Products’ ergonomic carts and movers are integrated into your workplace or production operation, full return on investment is typically realized within the first year or two through increased production and worker efficiency and decreased healthcare, disability and workers’ compensation costs.
  • Worker safety is one of the issues at the top of President-elect Obama’s to-do list. Stricter OSHA regulations regarding ergonomic issues are expected early in his administration. During his campaign, Obama promised workers a safer work environment which industry experts predict will mean tougher ergonomic standards and increased government oversight. Implementing an ergonomic program built around DJ Products’ carts, tugs and movers will put you ahead of the game as regulations tighten up. Ergonomically designed to take the physical burden off your workers, DJ Products’ carts improve workplace safety significantly.
  • Healthcare issues will be another key thrust of the incoming administration. Many of the plans being discussed in the press will increase the already difficult healthcare burden on employers. Ergonomic equipment is a proven way to significantly — and immediately — decrease employee medical, insurance and disability costs.

To be continued on Friday

Part 2: How DJ Products Can Help You Be a Survivor

Recently, we’ve been talking about the recession, workplace initiatives and increased regulation expected from the incoming Obama administration, and what it will take to position your business to survive the rocky road ahead. A tight grip on expenses, the willingness to embrace innovative ideas and technology, and the flexibility to take advantage of opportunities as they present themselves will be the hallmarks of companies that rise above the competition to succeed.

Many powerful issues will confront American business owners in the days ahead. Cost effectiveness, worker safety, healthcare issues, energy and environmental concerns, immigration and a changing workforce are among the challenges that we will face. Business owners who are proactive in addressing these challenges will position themselves to succeed. A leader in the design and manufacture of innovative, cost-effective, ergonomically-designed carts, tugs and movers, DJ Products can help you successfully meet the coming challenges. Continuing our Wednesday post, here’s how DJ Products can help you move ahead of the competition:  

  • Energy and environmental concerns are expected to take center stage with the Obama administration billing itself as the “green team.” Alternative energy products that decrease our country’s dependence on oil will receive increasing support as will products that decrease the nation’s environmental footprint. DJ Products’ battery-powered electric carts, tugs and movers use clean energy and have the staying power to work a full shift without recharging.
  • Changing workforce patterns are expected to create new challenges for businesses and industry as immigrant workers comprise an increasing portion of our country’s labor force. Language and cultural issues are expected to impact work environments and job efficiency. Intuitive ergonomic controls on DJ Products’ powered movers and carts make them easy to operate and control, bridging any potential language barrier. Our customers report an extremely brief and highly satisfactory training curve when our products are introduced into the workplace.

For complete information about DJ Products’ ergonomic carts, tugs and movers, visit our website. On our website, you’ll find a helpful Ergonomic Load Calculator that can help you or your company’s safety and health specialist estimate the amount of force necessary to move loads in your workplace. The program considers a number of variables specific to your work environment and makes product recommendations that can be used to improve both workforce and production efficiency.  Contact one of our industry experts today to find out how DJ Products can help you be a survivor.

Building the Workforce of the Future

Even before the economy took a dive, material handling industry experts were warning of coming changes to America’s workforce that could have far-reaching implications for U.S. businesses. America’s population is aging. By 2015, the over 65 population will increase by more than 20%. At the same time, the number of people getting started in the workplace, those 25 to 39, will grow by only 6%. And even more alarming, the population group that has traditionally formed the core of America’s workforce, those aged 40 to 54, will shrink by 5%. Businesses need to prepare now to deal with a younger, smaller U.S. workforce.

But that’s only part of the problem, said Gary Forger, Senior VP of Professional Development for the Material Handling Industry of America (MHIA), in his keynote address at ProMat 2009 earlier this month. The fast pace of technological change and the need for constant learning and retraining may present the biggest challenge. Where it used to take 12 to 15 years for skill sets to before becoming obsolete, it now takes less than 3 years. “It is estimated that 39% of the current workforce and 26% of new hires will have basic skill deficiencies,” Forger said. Unfortunately, America’s future workforce may not have the “live to work” ethic of their predecessors. Tomorrow’s worker will be seeking a better work-life balance, placing higher value on “work to live.”

While coming changes in workforce demographics will present significant challenges for U.S. businesses, Forger said it will also present unique opportunities to improve productivity and performance for companies able to exercise flexibility. Forger suggested that those opportunities are likely to be found in unexpected places. Companies may find it productive to pair old and new workers, he said. New workers would bring advanced technological skills to the table; older workers, knowledge and experience. Automation is expected to increase to allow smaller workforces to maintain production. The need to accommodate aging workers will place increased emphasis on ergonomic equipment.

As the number of U.S. workers dwindles, the material handling industry should prepare for an increasingly multi-cultural and multi-lingual workforce. Forger said recruiters may need to target new work groups, such as “Hispanic women reentering the workforce.” Retention efforts may need to become more flexible and more creative, offering different incentives to differently-motivated groups. In the future, advancement, employee satisfaction and responsibilities may provide better retention results than basic pay. How companies address work-life balance issues is also expected to play a key role in employee retention.

Ergonomic Scissors Lift Adjusts to Workers’ Heights

Bending, twisting and reaching all day long can have workers reaching for the Tylenol well before the day is over. These muscle-torquing activities lead to aches, strains and sprains that slow workers down and can eventually cause musculoskeletal injuries that entail multiple doctor’s visits, costly physical therapy and time off from work, placing an added burden on fellow workers who have to pick up the slack.

This was the problem being experienced by an Ohio manufacturer of aftermarket exhaust systems. Management noticed a high level of sprains and strains reported by workers. Investigation found the culprit to be the awkward positions workers assumed while performing production and packing tasks.

Workers come in different shapes and sizes but, as is true in most facilities, materials were delivered to work stations at a single, stationary height. Since few workers fit the “ideal” height around which equipment and tasks were designed, this meant that most workers, being either shorter or taller than the “ideal” height, were forced to bend, stretch, and strain to perform their work tasks. In the process, they overtaxed and injured muscles.

Company management sought a solution in ergonomics. Ergonomics is the science of fitting equipment and tasks to the capabilities of the worker to eliminate strain on the human body. Ergonomic design allows equipment that will be used by multiple workers to be adjusted to fit the size and capability of each individual. 

In the case of the Ohio exhaust manufacturer, the perfect solution proved to be an ergonomically-designed, portable scissor lift. The portable scissor lift allowed relatively heavy parts (120 lbs.) to be quickly moved from one station to the next. The power scissor feature permitted each worker to quickly and easily adjust the lift bed to the optimal height for his size. The result was virtual elimination of musculoskeletal injuries, an increase in productivity from 65% to 88%, and increased on-time delivery.

The problems experienced by this Ohio company are common to many industries, including manufacturing, fulfillment, packing, logistics, shipping and warehousing. DJ Products’ PWP2000 Cart Puller mobile electric lift table could be the perfect solution for your facility. Our ergonomically-designed, self-propelled electric scissor lift is available in a variety of shapes and sizes for various applications. Our lift tables deliver work items to the appropriate height every time. Combine our lift table with our PartsCaddy mobile platform truck and workers can easily move fully-loaded lift tables from one station to the next without physical strain. With 16 hours of battery life, DJ Products’ electric movers can stay in continuous operation through two shifts with ease. 

Teens Searching for Summer Jobs Must Think Outside the Box

If you have a teenager looking for a summer job, you know how grim their prospects are this year. Some employment experts are predicting that this will be the worst summer job market since the 1950s. Jobs usually held by teen-aged workers have been snapped up by laid off, furloughed, out-of-work adults looking for any way to make ends meet until the economy turns around. Tomorrow morning when you pick up your cup of coffee, take a look at the person manning the drive-through. You’re more apt to see a mature face than some fresh-faced high school kid — and the money-hungry collegiate workforce has yet to hit the summer job market. With traditional summer employers cutting back, teens and collegiates will have to think outside the box to earn money for tuition, car parts, clothes and dates this summer.

This is definitely a summer where teens and college students will have to look beyond the mall and local fast food franchises to find employment. It’s time to think outside the box! In years past, employment experts might have suggested that teens look for jobs in manufacturing. Unfortunately, the economic crisis has slowed U.S. manufacturing production, sending home thousands of U.S. workers and glutting the manufacturing workforce. There’s little opportunity in manufacturing this year for unskilled, part-time, summer laborers. But there is potential opportunity in fulfillment, distribution and warehousing, job experts say.

Not only do businesses benefit from cheaper labor when they employ teens and collegiates, but there can be advantages to building early working relationships with tomorrow’s prime workers. Summer jobs provide an opportunity for college students to try out potential careers while giving employers a chance to size up future workers. Many teens and collegiates return to a company summer after summer and eventually seek full-time employment. Savvy employers use these opportunities to pre-train future staff and benefit by gaining educated, top-notch employees ready to hit the ground running as soon as they earn their degree.

Distribution, fulfillment and logistics companies that utilize DJ Products’ highly-adaptable, ergonomically-designed material handling equipment won’t have any trouble giving this summer’s hungry teen workforce an opportunity to grow their work skills. Ergonomically-designed to adjust to the physical size and abilities of any worker, DJ Products equipment can be successfully used by male or female teens and college students without risk of injury. Intuitive controls, superior safety features, adaptable design, and premium construction make DJ Products’ motorized carts and electric tugs easy to use, minimizing training time and maximizing production — the perfect combination for summer workers! 

Electric Lift Table Puts Work Materials at Optimal Height

We all know how much faster and easier a job is when all our materials are at optimal height and within easy reach. It’s a minor annoyance when we have to lift a heavy object or stretch for tools when we’re at home doing the weekend warrior bit; but when we have to lift and stretch hour-after-hour on the job, that minor annoyance can quickly become a painful injury. According to the Bureau of Labor Statistics, overexertion injuries from repetitive lifting and awkward reaching cost employers an average of eight days of workers comp time per injury. That’s a pretty high price to pay for avoidable injuries.

Lifting injuries that cause pain and damage to the lower back are a leading safety issue in manufacturing, assembly, fulfillment, pick and pack, and numerous other industries. Ergonomics is the solution. Ergonomics is the science of designing equipment and tasks to safely accommodate the breadth of variety in the human work force. Ergonomic material handling equipment addresses safety issues created when workers of various sizes must perform the same work tasks. By making the individualization of work platforms possible, ergonomic material handling equipment minimizes the risk of injury from lifting, stretching and straining. DJ Products’ ergonomically-designed lift tables, scissors lifts and adjustable carts and platforms allow each individual worker to position materials at his personally-optimal work height.

Unfortunately, many plant operations were set up before manufacturers realized the importance of ergonomics in protecting workers’ health and safety, increasing productivity and managing costs. Fortunately, DJ Products manufactures a complete line of mobile adjustable lift tables, scissors lifts, carts and platforms. Our compact, battery-powered, electric lifts allow workers to lift materials and perform tasks at optimal work height, eliminating injury-inducing stress and strain. Contact DJ Products for complete information. We manufacture a full line of material handling products and can design an ergonomic solution to your unique problem.

Preparation Can Aid in Overcoming Unforeseen Obstacles

There are a number of things, out of your control, that can hamper your ability to get shipments out to your customers in a timely manner.   Any time you are bringing in products from a location that isn’t local, you can become the victim of shipping delays that can affect how quickly you are able to fulfill customer orders; and any time you are in need of an out of stock or made to order item, production delays can most certainly affect the prospected arrival date of materials.

Many of your customers may be understanding and not overly critical of you if the delays don’t impact their business too greatly, but others are only concerned with getting their order as quickly as possibly and don’t want to hear excuses of manufacturer delay.

Though your hands might be tied when it comes to manufacturer delays, you can help to offset these undesirable instances by being as prepared and efficient as possible in your own operations.  Properly trained and motivated employees who operate in a safe and organized environment with reliable equipment can turn around freight from receipt to shipment much more quickly and much more accurately than employees who work in a cluttered environment with outdated equipment that could be prone to breakdown.

Lifts and carts from DJ Products can handle a heavy workload for a full eight hour shift on a single charge and they are designed with the employee’s safety in mind.  All equipment from DJ Products is ergonomically designed to dramatically cut down on work related injuries and these lifts and carts make it easy for a single person to handle loads of material that would have required two people working with a manual cart.

You can’t control what happens outside of your facility, but by being as efficient and prepared as possible you can minimize the potential damaged caused by delays with quick and accurate actions within your facility.