Tag: Material Handling

Recognizing Opportunity in the Marketplace

The economic slow down has certainly presented its challenges, but it’s also presented business owners with a unique opportunity to reassess both their products and the marketplace. Savvy business owners are making good use of down time necessitated by decreased sales and lowered production to shift more resources into market analysis and research and development. It’s a move geared to discover new opportunities in the marketplace and position businesses to compete more strongly as the market recovers.

While it’s stripped to its bare bones, this is an excellent time to focus on the most essential aspects that drive the market in which you compete. And that’s a smart thing to do periodically, but a chore that is easily put off in the hustle and bustle of meeting customer demands and production schedules when the market is thriving and you’re focused on sales. While the economy is slow, you have time to focus on the essential needs of your customers and that can sharpen your insight into the primary forces that ultimately drive your business. The process provides opportunities to discover new and innovative ways to meet those needs.

In every industry there are core needs that drive business. Applying new technology to address those core needs allows you to offer customers a competitive advantage they can’t get from your competitors. A down market allows you the time to research and develop new technologies and applications that will allow your business to stand out from the competition and offer your customers a way to compete more effectively in their own markets. This is also a time to explore new applications for your products that can open new, untapped markets for your products. The creation of multiple revenue streams through diversification minimizes your business risk when the economy tightens up.

DJ Products’ own story provides an excellent example of how analysis of core market needs can lead to the innovative application of technology to create unique new products. Early on DJ Products saw a need for the development of ergonomically-designed material handling equipment. You have only to look at U.S. Bureau of Labor and Workman’s Compensation statistics to recognize the high cost in both production losses and worker medical expenses caused by musculoskeletal injuries from moving equipment and products in the workplace. Applying ergonomic design techniques to material handling equipment provided a unique solution that successfully resolved these issues, providing practical and affordable solutions to a core industry need. DJ Products’ continued dedication to developing unique solutions to meet customers’ needs has made us an innovative leader in the material handling industry.

Customers Find Unusual Applications for DJ Products’ Powered Carts

Here at DJ Products, we love to hear about some of the unusual and unique uses our customers have found for our motorized carts and powered movers. Often our customers’ inventiveness matches our own when it comes to finding new uses for our ergonomically-designed, compact and highly maneuverable CartCaddies.

S.B. of Sound Construction, who uses our versatile TrailerCaddy on job sites, found a unique personal use for his motorized vehicle mover during off hours. Boating and fishing are the big sports in his neck of the woods where nearly every driveway sports a boat on a trailer. Tired of the tedious back and forth maneuvering it takes to back a boat trailer into a narrow driveway, S.B. put his TrailerCaddy to use and easily positioned his boat in record time — and still had plenty of space to get the family car into the garage. His neighbors were so impressed, his TrailerCaddy is now in hot demand.

“No more must I watch the neighbors look like geeks trying to back their boats into the driveway — they simply borrow my TrailerCaddy,”  S.B said.

Often, customers come to us with a specific problem that challenges us to find new applications for our motorized equipment movers. We’re always pleased when our solution is a hit, as it was for J.A. of Wausau West High School.  

Lugging heavy, unwieldy, free-standing bleachers from one site to another was a problem for the maintenance crew at Wausau West High School. If you have ever tried to move one of these massive blocks of “portable” temporary bleachers, you know portability played second fiddle to sturdy construction when these units were designed. Unfortunately, the multiple uses to which schools must put their space demand flexible equipment use. Muscling bleachers into position for band concerts, school assemblies and various sporting events can tax the physical resources of even the stoutest maintenance crew. The risk of muscle and back strain and other injuries is high.

J.A. came to us seeking a solution. Our small profile, highly maneuverable, powered tugger, the CartCaddyShorty, proved to be the perfect solution. Capable of handling 3,000 pounds and maneuvering in tight spaces and crowded school corridors, the CartCaddyShorty allows a single worker to move and maneuver into place the school’s bleacher units in record time with no more backaches!

“Planning on spreading the work on this solution to the bleacher problem in other schools,” said a pleased J.A.

If you’ve found an unusual use for our equipment, we’d love to hear from you. And if you have a particular problem, give us a call. We love a challenge!

CartCaddy Tug Solves Auto Manufacturing Problem

The task was to design a robotic work cell to fabricate car doors. It was a difficult problem. The jig assembly that would hold the doors weighed nearly 5,000 pounds. The entire assembly would have to be pushed into the robotic work cell. The tier 1 robotics integrator for a major auto manufacturer turned to DJ Products for the solution.

DJ Products’ CartCaddy5WP tug was the answer. This powerful battery-powered tug allows a single operator to smoothly and safely change-out a finished car door with ease. State-of-the-art ergonomic design eliminates any potential injury to workers from manually pushing door assemblies into position. The tug’s powerful 36-volt motor provides effortless maneuvering of loads from 2,500 pounds up to 30,000 pounds. Highly maneuverable in tight spaces, this exceptional tug is equally effective in open spaces, hallways, aisles and assembly lines.

The CartCaddy5WP tug is a more powerful upgrade of our CartCaddy5W tugger. By adding weight over the drive tires, greater traction is created allowing the 5WP tug to manage heavy loads and equipment up to 30,000 pounds. This tug has the power to push or pull almost any heavy cart or piece of equipment.

In common application, the CartCaddy 5WP is used with carts or equipment having two swivel casters in front and two straight casters in the rear. Attaching the 5WP power tug to the swivel caster end of the cart/equipment allows the tug to easily power carts/equipment through turns and maneuvers, even in tight spaces. An ergonomically designed variable speed twist grip prevents carpal tunnel syndrome and allows the operator to maintain smooth control through intricate maneuvers in both forward and reverse at speeds of from 0 to 3 mph. For full specifications on the 5WP power tug, click here.

The electric lift option on the 5WP power tug raises and lowers the tug’s arm for firm attachment to the bottom of carts or equipment. With the arm attached, the tug can pivot a full 180 degrees under the arm, allowing loads to be turned 90 degrees without problem. The CartCaddy5WP power tug is among the most powerful, most maneuverable and most versatile tugs on the market. Click here for more information about the CartCaddy5WP power tug and a video of this tug in action.

Electric Carts Ease Strain of Push-Pull Tasks

Pushing and pulling are the two most required actions in industrial and business settings. Unfortunately, pushing and pulling can place extreme stress on a worker’s body, often resulting in back, groin and other musculoskeletal injuries. Injuries can cost an individual business thousands of dollars each year in medical, insurance, disability and lost man-hour costs. An ergonomically designed electric cart pusher and motorized cart puller eliminates the physical strain of manually pushing and pulling heavy carts and wheeled equipment. An investment in ergonomic equipment is a sound investment in the health and safety of your workforce that can save your business thousands of dollars in unnecessary medical and insurance costs.

In manufacturing and distribution settings, the most common solutions to material handling tasks are:

  • to place products, parts and equipment on pallets for handling or
  • to utilize racks, carts and casters to move materials.

Electric carts come in a variety of shapes, sizes and configurations to fit the demands of the task and the capabilities of your workforce. An ergonomically-designed cart mover reduces the amount of force that must be exerted by the operator to maneuver a load. Various cart and wheel configurations are available to meet the needs of any task.

  • Carts, racks or equipment with casters can be easily turned and maneuvered with a CartCaddy power tug that feature a 5th wheel turning method.
  • Carts, racks or equipment with 4 swiveling casters require a cart with back end control.
  • Specialized CartCaddies and an electric tug have been designed to handle carts or equipment that have straight wheels or are on a rail.

Visit the DJ Products website to view our complete line of ergonomic electric carts, trucks and lifts. We offer ergonomic solutions for material handling applications.

Manufacturing Rebound Glimmers on the Horizon

With the dawn of a new political era in Washington, U.S. industry experts are cautiously predicting that manufacturing’s darkest days are over and that a rebound can be expected within the next six months. Analysts seem to agree that the Institute for Supply Management Index (ISM) finally bottomed out and will now begin to grow.

“Much depends on some proposed government actions and the reaction of the financial community,” Chris Kuehl, an economic analyst for the Fabricators and Manufacturers Association, told writer Joe Cogliano in the January 6, 2009 edition of Manufacturing & Technology eJournal, “but assuming that the credit crisis continues to diminish there will be some recovery in certain sectors.”

In anticipation of President Obama’s promised economic initiatives to create jobs, rebuild infrastructure and move to alternative fuels, Kuehl expects businesses that supply construction material and machinery and those in energy development to lead the recovery. He said that media saturation about the dire straights of the automotive and construction industries has obscured any good news about the state of U.S. manufacturing. He noted that medical manufacturing has actually grown during the recession and that the aerospace industry has held firm. 

A double digit production decline in the 4th quarter of 2008 is expected to be manufacturing’s low point. The National Association of Manufacturers (NAM) predicts a continued but gradually decreasing decline across most industry sectors for the first three quarters of 2009 before the advent of slowly rising numbers. NAM expects the final months of 2009 to bring a 1.4% increase in manufacturing rates.

Experts agree that while economic downturns take a toll on industry, they also serve to cull out weak, mismanaged and antiquated companies. Those that survive are stronger, more efficient, more resource conscious and more productive. On a larger scale, benefits of the economic crisis include a new era of better risk and credit management by both lenders and borrowers, new avenues of industrial growth, and deeper understanding and a necessary re-evaluation of global trading relationships and their impact on U.S. economy.

“The challenge for all of us is to determine if this is a ‘disaster’ or an ‘opportunity,'” Norbert Ore, Chair of the Institute for Supply Management’s Manufacturing Business Survey Committee told Manufacturing & Technology eJournal. “If we choose disaster, we will be paralyzed during a period of great change, and we will assume that there is little hope of prosperity for ourselves and our organizations. If we choose opportunity, we can view this as the time to face challenges head on and find more productive ways to create value for ourselves and society.”

Six Sigma + Ergonomics = Productivity Gains

Implementation of a comprehensive ergonomics program is often initiated by a business for the obvious safety and financial benefits realized in reduced workplace injuries and their attendant costs. What many business owners fail to realize are the significant productivity gains possible when ergonomic practices and ergonomically-designed equipment are adopted. Businesses that practice Six Sigma have been quick to see the potential for sustained productivity gains when ergonomics are integrated into workplace practices.

Utilization of the 5-step Six Sigma process can help a business build a successful and sustainable ergonomics program that will not only produce impressive immediate production gains, but sustain and continue to improve those results over the long-term. Six Sigma practitioners have found that adoption of ergonomic practices and use of ergonomic equipment optimizes worker performance, reduces production cycle time, increases cost competitiveness, and empowers workers. The end result is increased production, improved product quality, a happier workforce committed to improvement, and a satisfyingly positive impact on your bottom line.

Six Sigma’s disciplined, process-oriented approach to problem solving involves five steps that are easily applied to development of a comprehensive ergonomics program:

Define. It’s important to know what you’re working toward, so the Six Sigma process begins by establishing the goals to be achieved. Clearly define the problems to be addressed by reviewing injury, illness and workers’ compensation claim data for commonalities. Production bottlenecks, quality issues, rework costs, and warranty costs are other problem indicators. Don’t neglect the important area of staff morale. High absenteeism is indicative of low morale. After defining problem areas, establish specific goals for improvement in each area. You’ll also need to determine tracking metrics and establish support and educational resources.

Measure. In order to correctly measure improvement, you need to pinpoint your starting point. Collect information about your workers and their abilities. Define the parameters and potential risk of each task, paying particular attention to potential stressors, including site lines, posture, reach required, force expended, repetition, vibration, noise levels, work environment temperature, etc. Collect data about the individual steps required to perform each task.

Analyze. Analyze the data collected to discover the root cause of each problem. Evaluate and identify risks associated with each task. Don’t neglect to talk to the workers who actually perform each task. They can provide astute insight into what works, what doesn’t and how to improve the situation. Before implementation, carefully evaluate potential process improvements, equipment and tools for their ability to solve the problem as well as risk potential. Determine and prioritize improvements to be introduced into the workplace.

To be continued Friday

Part 2: Why Businesses Fail

The economic slowdown, tight credit and high fuel costs are placing a sometimes fatal strain on businesses. This week we’re taking a look at why businesses fail. Those who learn from the unfortunate mistakes of others are more likely to succeed.  

Continuing our list from Monday of the most likely reasons businesses fail:

  • Inadequate sales. Inaccurate market analysis can lead to inadequate or inappropriate marketing/sales efforts. A business’ potential market share equals the total market potential for your product or service divided by the total number of competitors in your market area. When sales volume exceeds normal market share, you achieve market dominance and move beyond the break-even point into profit. Naturally, this is every businessman’s goal. While sales are the key barometer of business success, base business decisions on weekly and monthly averages, not daily volume. It’s business trends that drive future sales so concentrate on longer-term market analysis. 
  • High expenses. Failure to properly anticipate and budget potential expenses, failure to adequately control expenses and/or failure to constantly review and update purchasing/service contracts are all common money pits. Expenses should ever exceed income. Never consider any expense as fixed; every expense is negotiable. Be prudent in your purchasing policies. Stockpiling supplies, buying additional product already in stock and failing to decrease order quantities as demand decreases are common mistakes. Limit buying to what you need, what you’re using and what will increase sales.
  • Poor credit policies. Credit keeps business clicking along, but over-extended credit can lead to bankruptcy, particularly in today’s economy. Maintain good credit policies in your own borrowing and be clear about credit policies to customers. Clearly communicate credit policies to customers before finalizing a sale and don’t continue to offer credit to slow-paying customers. You could be left holding the bag.

To be continued

Proactive Problem Solving Reduces Workplace Injuries

Reducing workplace injuries is every responsible business owner’s goal. Not only do you value your employees’ health and safety, but the cost of ignoring workplace safety — high medical, insurance, workers’ compensation and lost man-hour costs — can be staggering. It pays to be proactive in looking for potential injury-causing problems and coming up with ergonomic solutions that improve the fit between the work and the worker.

Developing a proactive plan to reduce workplace injuries is a four-step process:

  1. Observe and question
  2. Set priorities
  3. Implement improvements
  4. Follow up

1. Observe and question.

Look for clues to possible problem areas in available statistical data. Check injury reports for patterns that indicate higher injury rates for certain tasks or in certain areas. OSHA logs, worker reports and complaints, absence rates, and workers’ compensation reports are good starting points. Ask if your workers’ compensation insurance carrier provides workplace assessment surveys as part of their risk-management services.  

Look at production reports for bottleneck areas. Check quality control reports for poor quality product or service. Problems can indicate areas where workers are having difficulty completing tasks effectively under current conditions. The root cause of such problems is often poorly designed equipment or task procedures.

Spend some time following the entire process of your business from start to finish. Pay particular attention to areas highlighted by the data review. Observe the way workers do their jobs. Watch for risk factors such as awkward postures, repetitive motions, forceful exertions, pressure points or extended periods spent in the same position. Watch for signs of worker discomfort or pain such as self-restricting movements, efforts not to move certain body parts or massaging hands, arms, legs, necks or backs. Pay attention to unnecessary handling and duplication of material or product movement.

Look for ways in which workers have modified standard procedures to make it easier to do their work, including modifications to tools, equipment, workstations or task performance. Talk to managers but also talk to the workers who actually perform the tasks. Ask workers how they would change the work process, operations, tools or equipment to make their jobs less physically demanding and more efficient. You’ll get a clear idea of what isn’t working and may get some excellent suggestions for improvement.

Continued next time

Part 3: Why Businesses Fail

The business section of the newspaper seems to carry daily notices of failing businesses. Despite tighter requirements, bankruptcies are up. Businesses are succumbing to a combination of the economic slowdown, tighter credit and high fuel costs. Today we continue our series on why businesses fail (see our July 14 and 16 posts).

Most business fail for a combination of reasons, including:

  • Poor collection practices. It’s not enough to make the sale; you have to collect the money. While this should be obvious, many businesses fail to initiate or maintain good collection practices. Just like sales, collections should be a daily task. The biggest mistake many businessmen make is to allow late accounts to go too long before starting the collection process. Many customers will take advantage of the traditional 30-, 60-,  90-day payment schedule. Try aging your accounts receivable by the 15th and month end or even weekly. The sooner you start collections, the better the chance of collecting and the faster your money turns over.
  • Lack of experience in basic business know-how. On-the-job experience is an effective teacher, but the lessons can be costly. Develop an ability to learn from the experiences of others. Education, keeping up with industry journals and publications and attending professional conferences and seminars can offset a lack of personal experience. Meeting with other businessmen through professional organizations or social/community service groups provides a valuable opportunity to discuss common business problems and issues.
  • Poor location. For retail businesses that depend upon walk-in or drive-by trade, poor location can be disastrous. Manufacturing and industrial concerns require easy access to freeways and other transportation routes for both delivery of raw materials and shipment of finished product. Convenience and visibility are key. 

    To be continued

Does Obama Have Muscle to Win Ergonomics Fight?

Like actor Mickey Rourke’s amazing return to the Hollywood ring in The Wrestler, labor is back; and President Obama is in its corner cheering its revival. After eight years struggling on the ropes during the Bush administration, labor has bounced back into the Washington ring and is gaining strength — and it’s bringing the ergonomics fight with it.

“I do not view the labor movement as part of the problem; to me it’s part of the solution,” President Obama was widely quoted as saying recently. During his campaign, Obama repeatedly promised American workers a safer, healthier work environment. Industry watchers have taken that to mean a return to and an expansion of the ergonomic standards initiated during the Clinton administration but quickly rescinded under Bush. With a Democratic-controlled Congress backing him up, Obama appears to have the muscle to force ergonomics back into the legislative ring.

By naming California Democratic Representative Hilda Solis as his new Labor Secretary, Obama appears to be saying to U.S. industry and the U.S. Chamber of Commerce, a long-time vocal foe of ergonomics legislation, “Bring it on!” Although she’s still running the confirmation gauntlet, Solis has received the recommendation of the Senate Health, Education, Labor and Pensions Committee and is expected to be confirmed, possibly as soon as tomorrow.

The daughter of immigrants and union workers, Solis has long ties to labor groups and has been a champion of ergonomics in the workplace since joining the House of Representatives in 2001. Her home state of California is the only state in the U.S. that mandates ergonomic standards that force employers to provide a safe and healthy work environment for their workers. Concerned about the cost of implementing ergonomic standards, those opposed to ergonomic legislation fear that California’s tough ergonomics rules will be used to create a national model.

That Obama would eventually grapple with ergonomics to improve labor conditions has been a given since his campaign days. But there’s been a lot of speculation in the industry and in Washington about how and when Obama would try to take down ergonomic opponents. By calling Solis into his corner, Obama seems to be getting ready to enter the ring. It will be interesting to listen to the President’s State of the Union speech tomorrow night. A direct statement about ergonomics or workplace safety could indicate that the fight is on!