Tag: Material Handling

Efficient Wheel Design Reduces Friction

Friction occurs when two surfaces come into contact, as when a wheel rests on a floor. Friction is the force that resists movement between the objects. Under theoretically perfect conditions, the ideal wheel environment would be a hard, smooth wheel rolling over a hard, smooth surface. In real life, perfect conditions never exist. In a typical work environment, using a hard wheel will often result in higher rolling resistance, as well as increased noise and vibration.

Both static and dynamic forces affect friction. The initial push force necessary to place an object in motion is the static force. Static force is generally greater than dynamic force which is the exertion necessary to keep the object moving. Wheel design must consider bother static and dynamic force.

In a wheel or caster system, there are three places where friction can affect force:

  • at the point where the axle and wheel interface;
  • if a swivel caster, in the swivel housing; and
  • at the ground/wheel interface, particularly at any points where the wheel will slide or pivot on a surface.

The efficiency of a wheel or caster in reducing friction is dependent not only upon the appropriate design of the wheel itself, but also on the materials used in its construction and the placement of the wheels on the equipment to be moved.

Prepare for Red Tape; Regulation Is Back in Vogue

As President-elect Obama prepares to take office, there’s a lot of talk about “accountability,” particularly in the face of the large handouts to the banking and now auto industries. It looks like Detroit’s auto makers are going to pay the price for the rather arrogant behavior of the nation’s financial institutions that were quick to take Uncle Sam’s money (actually your money and my money) but haven’t been so quick to tell us what they’ve done with it. Further handouts are coming burdened with rules, regulations and (this being the government) mountains of paperwork to ensure that the government’s money is being used the way they want it to be.

After years of deregulation, which economists say is partly to blame for our current predicament, the pendulum is starting to swing in the other direction. For at least the next decade or so, economic experts expect the U.S. to embrace increased government regulation. In fact, angry citizens, many of whom feel they’re being robbed to support bad business decisions and executive excess, are demanding greater regulation and more stringent government oversight.

Once his team settles in, industry experts expect to see the government sticking an ore in wherever and whenever the President thinks the economy or a particular industry needs a shove. And because of the government’s tremendous investment in the country’s banks and businesses, the President will consider it his right, perhaps even his duty, explained economic analyst Chris Kuehl in a recent Fabricators & Manufacturers Association, International newsletter. “The Fed is already more engaged in the U.S. banking system than ever before, and that involvement will likely expand,” warns Kuehl. “The Treasury Department is already a part owner of most of the major banks in the country, a leading insurance company, and perhaps, in time, the Big Three auto companies. That gives the U.S. government a major stake in the performance of its largest companies, which will mean direction and advice.”

So sharpen your pencils, add an extra box or two of paper to your office supply order this month and prepare to add a chair in the boardroom for Uncle Sam. It looks like the red tape is going to be flowing again!

Why Attend Trade Shows and Conferences?

Why should you attend trade shows and industry conferences? When the economy is tight and sales are down, how do you justify the expense of attending a trade show or conference, particularly when gas, airline and hotel expenses are climbing? My dad would tell you what every smart businessman knows: keeping up with industry developments and trends isn’t a perk, it’s a necessity.

I can remember when my dad attended MHEDA trade shows in the 1960s, ’70s and ’80s. For a man who worked 15-hour days 6 1/2 days a week, the annual trade show was his idea of a vacation. He always took Mom along to share the fun. She’d pall around with the other wives on day tours then meet Dad for dinner with other business friends. Dad spent his days boning up on new developments and new products, jawing with suppliers and  distributors, and picking the brains of other business owners — the 1960s version of networking. He always tried to work in an educational conference or two each year, and became a MHEDA presenter later in his career.

Dad placed a high value on education and keeping abreast of current developments and future trends. He preached planning for the future as the best way to grow your business. He believed in the power of networking, both as a resource for solving business problems and as a tool for growing your business. Industry trade shows and conferences give you the opportunity to stay current in your business, learn about future trends and network with industry peers. There couldn’t be better reasons to attend.

MHEDA is offering two fall events geared to revitalize your material handling career and make your business more productive:

The Young Distribution Professionals Conference August 3-6 at the Eaglewood Resort & Spa in Itasca, Illinois targets material handling professionals with less than 10 years in the distribution industry. The conference is designed to help rising managers increase their knowledge of distribution and expand their distribution career skills. There will be ample networking opportunities to interact with peers in the distribution and other material handling industries. A host of engaging speakers will focus on the development of leadership and management skills.

Parts & Service Management Conference September 11-12 at the Crown Plaza Chicago O’Hare in Rosemont, Illinois targets parts and service managers, branch managers and operations managers. The conference will focus on daily issues that arise in material handling parts and service departments. Sessions will teach attendees how to identify key performance indicators in their departments with an emphasis on profitability and customer service.

Ergonomic Wheel Design Improves Productivity

In our last post we talked about the importance of wheel design in reducing friction. But why is that important? The answer is that any design element that decreases the force that must be exerted by the operator to manipulate a piece of equipment increases efficiency and decreases the risk of potential injury. The result is greater productivity. This is the goal of ergonomic design both in the design of equipment and the environment in which it will be used.

When a wheeled piece of equipment is used, the operator must first overcome inertia and friction. The initial force necessary to start an object in motion is far greater than the sustained force necessary to keep it moving. Once in motion, optimum sustained, or rolling, force is achieved when a steady, constant velocity is achieved. Any need to decrease or increase velocity requires increased force to combat inertia. This is particularly noticeable during turning and maneuvering when significant force must be applied to change direction. Stopping a piece of wheeled equipment requires the same high level of force as starting it. As when accelerating, the operator must overcome high levels of inertia and friction to decelerate.

The four physical elements required to move a piece of wheeled equipment — starting, rolling, turning and stopping — can place tremendous stress on the operator’s musculoskeletal system. If performing these tasks manually, workers frequently overexert and strain muscles while applying the necessary force to start or stop a piece of equipment. Turning and positioning equipment can cause operators to assume asymmetric body postures during exertion which can cause musculoskeletal injury.

Ergonomically designed carts and tugs seek to achieve the optimal wheel size, type, placement and composition to decrease the force an operator must exert to move a piece of equipment.

Lifting Tips that Prevent Back Injury

In our last post we talked about the exorbitant cost of back injuries to industry. In both human and financial cost, back injuries take an expensive toll. Application of ergonomic principles to the work space and use of ergonomically designed equipment can reduce potential back injury significantly. But sometimes materials must be manually lifted and moved.

It’s important to train workers in proper lifting techniques. Musculoskeletal injuries, particularly to the lower back, can result when items are improperly lifted. The key to developing good lifting habits is to think about what you plan to do before picking up an object. Practice these safe lifting tips:

  • Size up the load and check surrounding conditions. Get help with the lift if the object looks heavy or awkward. Make sure you have good footing and enough space to maneuver easily. If the object must be carried, may sure your path is free and clear of obstacles.
  • Balance your body. Your feet should be shoulder width apart and beside each other. To provide maximum balance and leverage, your feet should be positioned somewhat behind the object to be lifted.
  • When lifting, don’t stoop. Bend both knees and keep your back straight but not vertical. Tucking in your chin will help you keep your back straight.
  • Use your hands and fingers to grip the load. Called a palm grip, this grip provides maximum security. Remember to tuck in your chin before you lift.
  • Use your body weight to get the load moving. Lift by pushing up with your legs, your body’s strongest muscle group.
  • Keep arms and elbows close to the body while lifting to provide better balance and maximize lift force.
  • If you must carry an object, carry it close to your body and don’t twist. Shift your foot position and turn your whole body to change direction.
  • Remember to watch where you’re going.
  • Bend your knees when lowering an object. Avoid stooping which places unnecessary strain on your lower back. Place the object on the edge of a shelf, bench or other surface and slide it back into position. Keep your hands and feet clear as you let go of the object.

Even when lifting or moving light-weight objects, it pays to develop good lifing and carrying habits. Your back will thank you!

Logistics Tops 10% of U.S. GPD

U.S. logistics costs just topped 10% of the country’s gross domestic product (GDP) in 2007. The recently released 19th Annual State of Logistics Report revealed that logistics costs for 2007 were just under $1.4 trillion. The report is sponsored by the Council of Supply Chain Management Professionals.

GDP figures for 2007 were up from 9.9% in 2006 and matched 1998 figures. In the intervening years, only 2000 resulted in a GDP figure above 10%. With the exception of 10.3% in 2000, total spending as a percentage of GDP declined steadily from 1998 to a low of 8.6% in 2003 before beginning a slow rise. Financial experts predict a drop in GDP spending figures for 2008 citing the slow economy, high fuel costs, the mortgage crisis and the resulting credit crisis.

The report indicated significant increases in total business inventories. In 2007 inventories rose 8.7% and an additional 3.7% in the first quarter of 2008. At 5%, commercial interest rates were at 5-year highs. Commercial paper rates were just 1% in 2003 and 2004.

Not surprisingly, motor carriage led logistics spending at $671 billion or 79% of transport costs and 48% of total costs. Motor carriage costs rose 6.1% in 2007. With diesel prices edging past $5 per gallon, 2008 carriage costs are expected to be significantly higher. Logistics companies and shipping firms are feeling the pinch of rising fuel prices. With no relief in sight, shipping companies are hurting and many smaller firms are going under.

Increased fuel prices are expected to have a deleterious effect on 2008 GDP figures. Logistics industry gains realized in 2007 may well be lost. How desperately the overall economic picture will be affected remains to be seen, but experts don’t think it’s looking good. Losses are expected across the board.

Congress Debates Increasing Fines for Worker Injury, Death

Congress is being urged to increase financial penalties for workplace injuries and deaths, according to congressional testimony reported by McClatchy Newspapers. In last week’s hearing before the U.S. House Education and Labor Committee, workers’ advocate groups squared off against industry safety experts to debate increasing penalties when employers don’t protect their workers against hazardous conditions.

Workers’ advocates pressured the federal government to drastically increase fines and implement possible criminal prosecution for senior executives when workers are killed or seriously injured on the job. “The thought process has to be, ‘If I keep doing this, and I keep letting this happen. … I could go to jail,'” David Uhlmann of the University of Michigan School of Law and a former U.S. Department of Justice official, told the House Committee.

Speaking for the opposing view, a workplace safety attorney who helps businesses figure out how to respond appropriately to U.S. labor laws, recommended more clearly defined labor safety laws and more stringent enforcement of existing penalties for employers who exhibit a “callous disregard” for workers’ safety. “There needs to be a balance,” Lawrence Halprin, a lawyer with Keller and Heckman, told the House Committee, noting that confusing labor regulations often contribute to the creation of workplace hazards.

Last week’s hearing was one more volley in the Congressional debate that is accompanying preparation of anticipated legislation to overhaul the 39-year-old Occupational Safety and Health Act (OSHA). With the Obama administration’s apparent blessing, House Democrats are preparing to give OSHA a new and sharper set of teeth. New regulations being considered would dramatically increase employers’ penalties, increase business owners’ accountability and protect workers who speak out about workplace violations. OSHA penalties have not been updated since 1990, and financial penalties were never indexed to inflation. Current penalties for the injury or death of a worker often total just a few thousand dollars.

“Penalties must be meaningful,” said Rep. George Miller, a California Democrat and chairman of the House Education and Labor Committee. “They must function to deter violations. They must get people’s attention.”

However, some committee members are concerned that their Congressional peers may be unduly swayed by the many stories of personal tragedy that have peppered the hearings. Rep. Tom Price, a Georgia Republican, noting that workplace fatalities have declined since 1994, said, “Sometimes Congress gets emotional and draws the wrong conclusions and makes the wrong laws.” Time will tell what happens here, but you might want to weigh in with your Congressman and tell him how you feel.

The Art of Solving Material Handling Problems

How do you solve material handling problems in your business? Often the people charged with solving a problem on the floor or in the plant have no experience actually performing the tasks that are involved. The biggest hindrance to problem solving in business or industry can be management’s tendency to rely strictly on reports and charts. Sometimes you just have to get your hands dirty. 

As they say, there’s no substitute for experience. For instance, say you want to improve order picking productivity. In most operations, pickers spend 60% of their time walking. Obviously, measures that will reduce walking time will increase productivity. On paper transport routes can be planned, inventory placement can be allocated, cart loads can be configured and assembly points can be designated to presumably increase worker efficiency. On paper everything can look great, but on the floor reality can sabotage the best laid plans.

We’re not saying planning isn’t important. Of course it is. But it should be considered a starting point, not an end product. Before final implementation, you should take your plans for a test drive. Give ideology and reality a chance to meet. You’ll usually find that when put into practice paper plans need some serious tweaking to ensure that they achieve the desired results.

In our order picking example, picking items may not actually be located where expected due to warehouse concerns or overstock issues. In the picking area, items may not be optimally located. Picking bins may require workers to reach or stretch unnaturally, risking potential injury and decreasing productivity. Individual productivity can vary greatly between workers, particularly between seasoned and new employees. Picking items may not be transported to pick areas at an optimal rate. Transport surfaces can present their own challenges. Rough or sloped surfaces can decrease efficient transport. Batch sizes may not be optimally configured. Large batches or items may require transport on multiple carts. Reconfiguration to optimize cart loads can increase efficiency and productivity. While these issues may not be obvious on paper, they are obvious in practice and present considerable obstacles to efficiency and productivity.

Next time you work to solve a material handling problem in your business, spend some time walking in the shoes of your workers before you implement a final solution. It’s a sure way to guarantee success.