Warehouse Best Practices

7/28/2019 Warehouse Best Practices

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Getting the most from your warehouse or distribution centre

WAREHOUSE S P R I N

G 2 0 1 2

ATLET In the pink and blue at

Kiddicare

BITO The right fit for NEXT

BRIGGS Matching Senators growth

CENTRAL SYSTEMSAdding value to the

3PL supply chain

COGRI GROUPPassionate about

warehouse flooring

JUNGHEINRICHPass the port test

BEST PRACTICE


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In business its never tooearly to start thinkingabout your successor

For details of this and other UKWA member services,please contact Michael Davison on (tel) 0207 836 5522

UKWA members have access to FREE business advice

If youre considering succession planning, mergers and acquisitions or

exiting your business, UKWA members have access to a team of experienced professionals who can guide you every step of the way

Call UKWA on 0207 836 5522for further information


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WAREHOUSE BEST PRACTICE www.ukwa.org.uk

Warehouse Best Practice 3

W elcome toWarehouse Best

Practice - a unique case-study based publication dedi-

cated, as its title suggests, to logisticsand materials handling best practice.

Featuring articles devoted to a singlevital aspect of the intralogistics functionwithin the logistics and supply chain

space it aims to highlight examples of products and/orservices that have brought operational benefits to the

warehouse environment.Of course, members of UKWA the trade associa-tion that represents the interests of almost 700 special-ists logistics service providers - undertake an exception-al range of warehousing and added value services -from animal feed storage through bonded warehous-ing to e-fulfilment. But, regardless of the areas in whichthey specialise, the Associations members all share adetermination to drive up professional standards in thewarehousing sector.

To become a member of the Association, all appli-cants must undergo a rigorous inspection by a UKWA Council official to ensure that they operate to the high-est minimum standards in 11 critical areas of ware-housing.

Only by demonstrating that it can comply with thesestandards will a companys membership application beaccepted and, to ensure that the highest levels of per-formance are maintained, UKWA members are expect-ed to participate in an annual operational audit pro-gramme.

Launched in 2005, UKWAs ground-breaking auditscheme provides users of third party warehousing serv-ices with a guarantee of professional competency.

The Annual Audit or AA as it is known was

devised by the UKWAs Operations and Safety commit-tee in response to a groundswell of opinion that mem-bers should be asked to undertake regular operationalaudits as part of their conditions of membership.

The Annual Audit is a self-assessment scheme basedon UKWAs existing and proven Standards of

Warehousing. Member companies undertake the auditthemselves and submit their report by a given dateevery year. Compliance is acknowledged by use of the

AA logo.UKWA members have responded enthusiastically to

the AA scheme and the overwhelming majority of mem-bers have successfully completed the process.

But, while membership of UKWA is comprised pre-

dominantly of third party warehousing and logisticsservice providers, membership eligibility criteria is nolonger restricted to companies operating in the thirdparty logistics and warehousing sectors. This means thatretailers, manufacturers and wholesalers are free to joinUKWA and compare best warehousing and logisticspractice with the leading companies in the logisticsfield. Furthermore, UKWA also welcomes membersfrom outside the United Kingdom's borders into itsmembership.

The Association is also open to suppliers to thewarehousing and logistics sectors who can join as

Associate Members. It is UKWAs firm belief that by maintaining close working relationships with all aspectsof the industry, UKWA will maintain its position at thevery heart of the logistics industry.

The UK logistics industry is an essential part of thecountrys economy and plays a pivotal role in domesticand international commerce. With its remit to serveboth 3PLs and those companies that operate their ownwarehousing and transport facilities, UKWA is a power-ful voice for the whole industry and its members arededicated to best practice in the warehouse.Roger WilliamsChief Executive Officer, UKWA

To learn more about UKWA and its activities visit www.ukwa.org.uk or telephone 0207 8365522 to request membership details.

Dedicated to BestPractice in the

warehouse


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WAREHOUSE BEST PRACTICEwww.ukwa.org.uk

A recent question on Linked-In askedGroup members for their top threewarehouse cost reduction strategies.There were over seventy replies and I thoughtit would be good to consolidate them into atop ten list of suggestions. The top ten areas follows based on their popularity.1. Training

2. Labour Management3. Process improvement4. Staff involvement and incentives5. Warehouse layout6. Provision of equipment

7. Utilities management8. Use of technology 9. Damage reduction10. = Fixed cost negotiation and reduction(Rates, Insurance)

= Health and Safety = Use of tools such as 7S, Six Sigma,

Kaizen, ABC and Gemba Kanri= Good Housekeeping

As labour is the largest cost area in anon-automated warehouse it is not surprisingthat the top four suggestions hone in onlabour related issues. Training was men-tioned regularly within the discussions, bothin terms of improving productivity, reducingerrors and damage and understanding theimportance of health and safety within thewarehouse environment.

Labour management followed closely with many suggestions concerning matching

labour hours to activity and work flow. Thiscan be achieved by employing both part timeand full time staff, supplemented by fully trained agency workers, utilising the concept

How toreducewarehousecostsUKWA board member, Gwynne Richards,

offers some advice on reducing costs in thewarehouse

of annualised hours and multiskilling thecurrent labour force.

The continuous review of processes alsoscored highly. The often heard phrase ofweve always done it that way was defi-nitely not part of the vocabulary of thosewho suggested reviewing warehouseprocesses regularly, observing staff closely inorder to identify bottlenecks and idle timeand as a result improve productivity andpotentially reduce overall labour cost. Theirmantra was more likely to be record,understand and improve.

The involvement of the warehouse staff inimproving processes and reducing idle timewas also seen as being crucial to attainingbetter productivity rates. Transparency, com-munication, accountability and incentiveswere all seen as enablers to achieveimproved performance and reduced costs.

Excessive travel time can increase labourcosts within the warehouse and therefore the

use of slotting techniques to ensure that fastmoving items are in the most accessible loca-tions and are close to the shipping area areessential to reducing unnecessary movements.

4 Warehouse Planning


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WAREHOUSE BEST PRACTICE wwww.ukwa.org.uk

The efficient layout of a warehouse canbe instrumental in reducing travel time,improving space utilisation and reducingaccidents. Allied to this is the provision ofthe most appropriate equipment, at theright cost and maintained to the higheststandards.

Equipment downtime or worst still equip-ment obsolescence can increase costs andadversely affect warehouse operations.

With significant increases in energy costsover the past couple of years, companiesare now looking closely at their utility billsand trying to find ways of reducing thesecosts. Large savings can be made by intro-ducing low energy technology to reduceheating and lighting bills. These include: Increasing the amount of natural light ina warehouse Turning lights off in an unoccupied area Replacing existing lights with energy effi-cient lighting

Replacing or cleaning roof lights The control of space heating systems Regular maintenance

Other areas include recycling water and

burning waste to produce energy. At numbereight in our list we have the introduction oftechnology. Within this area I have included

Warehouse Management Systems (WMS) andpicking technologies such as voice picking andpick by light. There is no point in introducingtechnology for the sake of it. Companies mustcalculate the return on investment to ensurethat their introduction will save cost over time.

The introduction of a WMS and an associat-ed Labour Management System can, in the rightcircumstances significantly improve productivity and as a result reduce overall costs. A realtime WMS can assist managers with achievingimproved picking performance and accuracy,

produce effective warehouse layouts and pro-duce productivity reports enabling managers toidentify areas for improvement.

Damage within the warehouse can be alarge cost area. This includes damage to thefabric of the building, damage to racking andequipment and also product damage. The lat-ter can result in many additional costs and thepotential loss of a client if it occurs frequently.

The remaining cost reduction suggestionsinclude improved health and safety within theworkplace, better housekeeping, negotiation

on fixed costs such as rent and insurance andfinally the use of tools such as an ABC analysisto lay out the warehouse and identify the crucialcost saving areas and the use of lean manage-ment tools such as Kaizen, 7S, Six Sigma andGemba Kanri to identify potential waste withinthe operation.

These thirteen suggestions are much as Iexpected them to be. The concentration on thepeople aspect is essential as labour is a signifi-cant cost factor within the warehouse.

One area which wasnt put forward was thedesign of the product packa ging, incl udin gits size, weight and durability. Get thiswrong and this can have a very significanteffect on warehouse storage and han-dling costs. Glen Vincent summed it upbrilliantly when he mentioned the impor-tance o f the letter P in reducing warehousecosts. His focus is on People, Products,Packaging, Pallets, Planning, Productivity,Processes and Procedures.

Gwynne Richards is a Director of Apprise Consulting Ltd, a supply chain consultancy and

training company. He is also author of Warehouse Management a complete guide to improving efficiency and minimising costs inthe modern warehouse published by KoganPage.

Warehouse Planning 5


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6 Forklift Fleet Management


Briggs Equipment UK is the national dis-tributor of Yale Europe MaterialsHandling products in Great Britain, pro-viding a wide range of equipment for abroad customer base. With its headquartersand national support centre in Cannock,Briggs people assist and advise in the deliv-ery of long-term solutions that enable cus-tomers to develop more efficient and resultsdriven businesses.

One of these businesses is SenatorInternational, the UKs largest manufacturerof office furniture equipment, which has seenproduction of tables and desks increase sig-nificantly over the past ten years. To keep upwith demand for its products, Senator hasneeded to constantly expand and adapt itsLancashire-based production facilities andthroughout a decade of sustained growth ithas relied on Briggs to provide materialshandling solutions that ensures productivity ismaintained and improved.

The latest development at Senator is theopening of a new production and warehousefacility at its existing site at Huncoat, near

Accrington. Here the company manufactures

Senator growthmatchedby Briggs

servicea wide range of office chairs and relatedproducts. One of the companys six sitesacross the UK, the Huncoat plant, has beendesigned from scratch to provide a morestreamlined production process.

Key to the success of the 6,480 sq. mfacility has been the introduction of the latest

Very Narrow Aisle (VNA) trucks from Yale,supplied by Briggs as part of an on-goingsupply and maintenance contract.

The MTC man-up turret truck from YaleEurope Materials Handling is technically advanced with simultaneous, independentand proportional hydraulic control. Thismakes it both fast and smooth to operate,vitally important for operator confidence atheight and for increasing picking speed. Itcan pick at heights of up to 17metres oneof its unique features that is market leading.

Additionally, the regenerative braking andlowering help to maximise the periodbetween charging, reducing costs and CO2

emissions whilst maximising productivity.Mark McDonnell, Senator Stores Manager,explained: As well as supplying the VNA trucks, Briggs and Yale played an important

To keep up with demand for its products, furntiure

manufacturer Senator relieson Briggs Equipment toprovide materials handlingsolutions that ensureproductivity levels aremaintained and improved

AT AGLANCEUSER: Senator InternationalINDUSTRYSECTORSERVED:ManufacturingEQUIPMENTSUPPLIER:Briggs EquipmentUKRETURN ONINVESTMENT:Productivitylevels improvedat manufacturingcentre


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Forklift Fleet Management 7

role in the development of the facility.Together they spent a lot of time researchingand sourcing the best flooring.

For a successful VNA operation, the cor-rect flooring is a critical component if theequipment is to operate safely and efficiently at maximum speeds.

Mark went on to explain how the four new VNA machines are required to move andstore around 1,000 pallets every week andservice 9,932 pallet locations across the newsite. These pallets contain the componentsand raw materials needed for the manufac-ture of the companys chair products. Oncethey have been unloaded, they are moved tothe storage section of the facility before beingfed onto the on-site production line.

For the operation Briggs came up with asolution that maximised available storage space,which has racking to a height of around 11.4metres whilst ensuring pallet movements arecarried out safely and efficiently.

Tony Worrall, Key Account Manager atBriggs Equipment said we have suppliedSenator with four market-leading Yale MTCtrucks that boast a number of significant

built-in safety features. The system we devel-oped also uses RFID tags in the floor coupledwith an advanced control system within thetrucks. This not only provides more confi-dence for the operator but also allows morecontrol of operations in the aisles.

The RFID system provides control of thetruck at the ends of the aisle, giving the oper-

ator greater confidence in operating at ahigher speed when in the aisle. At the pick-and-drop end of the aisle, the operatorknows the truck will slow and stop in thesame place. This allows pallets to be placedor picked more efficiently and increases safety at the end of the aisle. The system also con-trols the truck at the blind end of the aisle,assisting the operator in keeping the truckaway from a firewall, increasing stop clear-ance when the operator and truck are facingthe opposite way along the aisle. Lift height

limits are also controlled, per-aisle with theRFID system. Additional features of the Yale RFID system

include the ability to control speed within aspecific area of a specific aisle. The floor isextremely good at Senator, but other facilitiesnot so equipped will benefit from targetedspeed reductions in problem areas whichwould reduce the likelihood of damage to therack, floor or truck. The system slows thespeed in the problem area and then allowshigher speeds elsewhere, improving produc-tivity and operator confidence. Along thesame lines, the system can also be pro-grammed to ensure lift limit heights are setaround an obstacle, such as lighting, heatingor building structure.

The advanced wire guidance system of theYale MTC enables large acquisition anglesduring wire pickup and the operator can eventake his hand off the wheel and the truck willguide itself in. As well as saving time and cor-rectly positioning the truck to access an aisle,the system also reduces the risk of damage toracking. The unique antenna and system

design of the Yale MTC wire guidance alsoallows the VNA to run at speeds of 12 Km/hwhen in-aisle.

Other key benefits of the Yale MTC equip-

The RFID system provides control of the truck at the ends of the aisle, giv-ing the operator greater confidence inoperating at a higher speed when inthe aisle


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8 Forklift Fleet Management


ment includes the ability to operate in aislesas narrow as 1470mm and lift weights of upto 1,500kg to a height of more than 15m.

Mark continued: The new Yale VNA hasbeen very well received by the operators whoappreciate the extra comfort and ease ofoperation. They have been particularly impressed by the open front design that givesthem an unobstructed view of the area they are operating in. Although it is still early days, we are already seeing a significantimprovement in terms of efficiency and thewhole production process operates produc-tively.

Whilst the specification, performance andreliability of the VNA trucks have impressedSenator, they were not the sole reason thatthe company continues to work so closely with Briggs.

Across its six manufacturing and distribu-tion sites, Senator operates a fleet of more

than 50 forklift trucks, a fleet that hasincreased in size alongside the companysgrowth.

Briggs has provided the flexibility that we

Over the past decade, Briggs hasbeen more than just a supplier,it has been a real partner thatunderstands the needs of our business and tailors its services to

meet those requirements

have needed, expanding their service to usin-line with our own development, Marksaid. At key stages in our expansion they have provided the most appropriate materi-als handling solution. More importantly, theafter sales service from Briggs has been

exceptional. We have our own dedicatedengineer who is on hand at all times to dealwith any problems at any of our facilities andhis knowledge of our business helps to keepthings running smoothly.

Moving forward, the company is nowreplacing its existing fleet with the very latestYale equipment.

Over the past decade, Briggs has beenmore than just a supplier, it has been a realpartner that understands the needs of ourbusiness and tailors its services to meet thoserequirements, added Mark.

Key to Briggs on-going success is thestrengthening of its partnership with YaleEurope Materials Handling and the imple-mentation of a number of new initiatives. Thisincludes the launch of the Briggs Academy a training programme designed to help staffreach their full potential in their careers,which is due to be introduced later in theyear.

I strongly believe that the academy initia-tive is something that is essential for the busi-ness to adapt to future needs of our cus-

tomers, comments Richard Close, CEO atBriggs Equipment UK Ltd.For further news and stories on Briggs

Equipment please visit www.lifttrucknews.net

BriggsEquipment UK isthe UKs leadingindependentservice provider and materialshandling equip-

ment supplier.From a singleday hire pallettruck to longterm fleet man-agement solu-tions, Briggsoffer equipmentand solutionsdesigned toreduce costsand increaseproductivity

ABOUT BRIGGSEQUIPMENT


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www.briggsequipment.co.ukTel: 03301 23 98 14

Delivering ongoing innovationand expert eet managementwith true customer focusRichard Close - CEO

...for movable objects

BRIGGS

the irresistible force...


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10 Warehouse Trucks


Lifetime costs and the quality of truck per-formance and support convinced baby supplier Kiddicare to pick Atlet trucks forits rapidly growing single-site warehousingand retail operations. All the trucks are fin-ished in Kiddicares distinctive blue and pinklivery. Atlet supplied three advanced ForteUHS reach trucks to operate in double-deepracking areas and four Presto PLP pallettransporters configured as mobile pickingstations.

We liked Atlets approach, says StevePoulter, Kiddicares general manager. They provided the best package in terms of truckperformance, life-time costs and support.

Kiddicare has grown to be the largest pri-vately owned nursery and baby supplier inthe UK since it was founded in Peterboroughin 1974. The business expanded dramatically following the launch of its successful websiteand had outgrown its existing facilities. In2008 Kiddicare consolidated operations into

a purpose-built 27,900 sq metre (300,000sqfoot) integrated distribution warehouse andretail showroom, a unique concept in thenursery and baby retail sector . The show-

Atlets inthe pinkand blue at

Kiddicareroom is the largest of its type in Europe, cov-ering 5575 sq metres (60,000 sq foot) onthree floors and stocking thousands of differ-ent lines.

Our existing warehouse was fragmentedand old fashioned with block stacked palletsand no proper use of space, says StevePoulter. Here the aim is to utilise all theavailable space, have everything under oneroof and keep things very simple.

Every aspect of the operation has beendesigned from the ground up to support stockavailability and high throughputs. Many ofKiddicares fastest moving lines are suppliedfrom manufacturers in the UK and overseas incontainerised shipments with pallets often hold-ing identical products. Kiddicare recognised thatdouble-deep storage to the full 11m height ofthe warehouse would allow it to maximisecapacity without unduly compromising its ability to access items.

Double deep is ideal for high volumes of

fast moving stock and now we can hold somuch more, says Steve Poulter. But its alsovery easy to run a pick and pack operationhere because of the way were organised.

Lifetime costs and the qualityof truck performance and

support convinced babysupplier Kiddicare to pickAtlet trucks for its rapidlygrowing single-sitewarehousing and retailoperations. All the trucks arefinished in Kiddicaresdistinctive blue and pink livery

AT AGLANCEUSER: KiddicareINDUSTRYSECTORSERVED:Childrenswear retailEQUIPMENTSUPPLIER:

AtletRETURN ONINVESTMENT:Increased stockavailability andhigher throughput


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Warehouse Trucks 11

The company approached a number ofwarehouse truck manufacturers for adviceand recommendations. Atlet proposed threeof its advanced Forte UHS reach trucks con-figured for double deep pallet handling andfour Presto PLP stand-on powered pallettransporters.

We looked at a number of truck manu-facturers, says Jo Wright, Kiddicares partnerwith responsibility for procurement. The Atlettrucks looked good and we visited a number ofreference sites to get feedback from drivers, whotold us they liked them. We saw that the truckswere very reliable and had the facility to workdouble-deep to the full height in our warehouse.

When Atlet told us we could have them in ourown colours it showed they took a real interest inour business.

The double-deep section of the warehouseruns along five aisles accommodating 3336pallet locations. The racking is organised intozones, by supplier, for simplicity. The reachtrucks are used for putaway, pull down,replenishment and other handling tasks. Oneof these is to move isolated and small groupsof pallets into spare locations to free up con-tiguous space along an aisle so that the full

contents of an incoming container can bestored together.This was a new type of warehouse for us

and Atlet provided lots of advice, says StevePoulter.

The double-deep section occupies thelargest proportion of the warehouse. Othersections, known collectively as the tower,provide 1216 picking points in high density shelving for small packs, live roller-beds forlarger items such as prams and pushchairs,and an area at ground level with convention-al racking for furniture and other bulky prod-ucts. A conveyor system runs around thetowers perimeter and transfers orders to aconsolidation area where they are preparedfor delivery. No single item weighs more than30kg and everything is designed to ensureKiddicare can meet its next day delivery tar-gets for any item ordered before 5pm. Thecompany is currently despatching around1500 orders a day, well up from the 300 thatwas the norm just a couple of years ago.

Larger items are picked at ground levelusing one of four Atlet PLP ride-on powered

pallet transporters. These have beenequipped with a barcode scanner and printerwhich allows operators to verify and label anitem as it is picked before transferring it to

the despatch area.Each of the operators has a designated

truck and this encourages them to lookafter it. They can take full advantage ofergonomic design features to set up thereach truck as they want, for exampleadjusting the position of the seat, armsupport and head rest for comfortable

and efficient working. This is an importantfeature as the trucks are used from 8amto 6.30pm each day. The operators alsolike the camera mounted on the fork car-riage which allows them to see the rack-ing and load on a screen on their con-soles when handling pallets at the fullheight.

These are fantastic bits of kit and wewouldnt change them, says Steve Poulter.We like good quality and things to lookmodern.

Atlet provided operator training.Regular routine maintenance visits by locally-based engineers are complement-ed by a same-day call-out service. Thecompany provides Kiddicare with regularreports on truck maintenance, reliability and performance.

We need to keep running but if atruck is down someone will be here withinthe hour, says Steve Poulter All-in-allweve had no problems and the truckshave been reliable.

Kiddicare has invested in the equip-ment, technology and processes to sup-port and drive business growth. Stockcontrol used to be paper-based but is nowfully computerised and integrated acrossthe whole business with a resultantimprovement in performance. For exam-ple, customers in the showroom can orderany item from a cash desk or one of theself-service kiosks located in the variousareas. They can choose to take items withthem or have them delivered to theirhomes. Either way, the cash desk and

kiosks are linked directly to the back officeand warehouse systems to ensure aseamless and instantaneous transfer ofinformation. Items selected by customers

Each of the operators has a designatedtruck and this encourages them tolook after it. They can take full advan-tage of ergonomic design features toset up the reach truck as they want

Atlet is one of Europes leadingtruck manufac-turers and mate-rials handlingexperts and iscommitted toimproving the

profitability of itsclients materialshandling opera-tions. The com-pany offers arange of counterbalancedand warehousetrucks which areproduced at

Atletsheadquartersand

production plantoutsideGothenburg,Sweden.

ABOUT ATLET


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12 Warehouse Trucks

to take away are prioritised and pickeddirectly to a special collection zone on theshowroom.

Deliveries are designed to work aroundthe needs of mothers with young children.The company currently stocks around 5000SKUs but expects this to rise to over 6000 inthe next year or so as the baby retail sectorcontinues to grow. Kiddicare already achieves near 100 per cent customer satis-faction ratings but is always aiming toimprove. Track-and-trace technology enablesone hour delivery slots to be offered to cus-tomers. The companys systems provide ahuge amount of data on internal perform-

ance, such as pick rates, fulfilment levels andreturns. But it also focuses on informationabout, and feedback from, customers so thatit can target actions where they have thebiggest impact.

Weve put in a huge amount of time andinvestment to take the business forward andwe are expanding and volumes are increas-ing, says Steve Poulter. We always look tobuild close relationships with suppliers but wewont tolerate poor performance. Atlet hadthe answers and solutions to help us grow.

www.atlet.co.uk

New reach trucks combine ergonomic

performance and comfortThe new Atlet Tergo range comprises five advanced reachtrucks designed to provide the most ergonomic, effi-cient and productive performance in all types ofmaterials handling operation. The trucks havemaximum working loads from 1200 to 2500kgand lift heights up to 12.1m to provide opera-tors with total flexibility and choice across acomplete range of applications. The most pow-erful trucks in the range are designed to stack higher, heavier and faster in the mostdemanding and intensive 24/7 operations

such as retail and food distribution. Thesmaller and compact models aredesigned for operations where lighterloads and lower lifting heights are thenorm, such as newer and growing business-es, and include the first reach truck from Atlet to offer1200kg capacity.

Each model is packed with features - such as a mini steer wheel with floating arm rest and a a unique, ergonomicpatent-pending backrest that can tilt up to 18o to reduce neck and back strain when handling at high levels - designed tomake them the most ergonomic and personalised trucks onthe market.

atlet.co.uk/servicePhone: 01844 219282

E-mail: together @atlet.co.ukTo us service is not just about arriving first.Its about leaving.... your truck fixed.Atlet trucks provide outstanding up-time thanks to high quality constructionand parts standardisation. These parts are carried by our service engineersand an exceptional first visit fix rate is the result.

Visit our website and watch what Charles of BTC activewear says, and findout yourself


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atlet.co.uk/changePhone: 01844 219282E-mail: [email protected]

The time is always right to make a wise decision.Do you know there is a potential for improvement in your warehouse, but you just do notknow how to apply it? Does frustrating down-time occupy your day, or do you hold on toyour old systems and applications? Well, then its time for a change.

With more than 50 years of warehouse logistics knowhow, Atlet is a change for the better.Were ready to help you find and fix your bottle-necks.Call Chris 01844 219282 to find out how.

Ca n t y ou see I m t oo bu sy t o see a sa lesma n!


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14 Picking Systems


BITO has provided Next Group Plc with astorage solution comprising a range ofequipment that significantly improvesthe retail chains order picking options on itsrecently installed timber mezzanine floor.NEXT erected the 70 m x 300 m mezzanineat its 700,000 sq ft Dearne Valley automatedpallet warehouse, near Rotherham, inOctober 2010 to give 210,000 sq ft of addi-tional space following significant growth of itsHome business.

Next had planned that a timber mezza-nine could be installed retrospectively follow-ing the DC opening in May 2008. The DC isused to distribute the retailers Home goodsto its network of retail stores as well as itsDirectory business.

Working closely with Next, BITO devel-oped a racking solution that would work witha fleet of special Automated Guided Vehicles(AGVs) supplied by JBT Corporation to per-form pallet movement duties, such as replen-

ishment and extracting empty pallets from thepicking positions. Having tendered for thepallet racking scope, BITO subsequently designed the special order picking carts,

BITOprovidesNext withprecise

storage fitwhich it equipped with detachable steps.

BTs forkless AGVs are significantly lighterthan normal pallet handling AGVs (whichwould be too heavy to use on a timber mez-zanine). Instead of forks, these AGVs have atable that simply raises and lowers, so eachvehicle needs to position this table beneaththe pallet to pick it up. BITO designed theracking so that pallets rest on ledges runningbetween the uprights. The runners are posi-tioned high enough in the floorless pallet bay to allow the AGV to position its table rightinside the bay and beneath the pallet so thatthe table can raise to lift the pallet up, for the

AGV to extract it, or lower to place the palletdown on the runners.

BITOs pallet racking is configured with asingle pallet bay level with shelving above toprovide locations for unpalletised returned tostock items. Nexts operatives pick ordersinto BITOs specially designed pick carts. Thedetachable ladder, which can be switched

from one cart when it is full to the next,allows staff to reach the shelves above thepallet bay. As the cart fills up with orders,staff can raise a netting fence around the

BITO Storage Solutionshas worked closely with Next

Group Plc to design a solutionto suit the retailers preciseneeds for picking and packingon a new 210,000 sq ft timber mezzanine

AT AGLANCEUSER: NextGroup PlcINDUSTRYSECTORSERVED:Fashion retailEQUIPMENTSUPPLIER: BitoStorage SolutionsRETURN ONINVESTMENT:Enhanced order picking flexibilityand pickingaccuracy


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Picking Systems 15


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16 Picking Systems


top of the cart, which allows more items to beplaced into the cart without the risk of themfalling out. Separate carts are used for collectingwaste plastic and cardboard and are located ina pallet bay at the end of the aisle.

BITO worked on the idea of making theladders removable because Next wanted tobe able to leave a trolley, which is effectively the size of a pallet, to be picked up andmoved by the AGV as if it were a pallet. Thepick trolley features spring loaded cartwheels, so as the AGV picks up the trolley,the wheels will flick into line to stop themmoving and prevent them catching as the

AGV departs. BITO worked with NEXT todevise a design that met all requirements.The solution involved a lot of engineering

and BITO excelled in both understanding the

Because BITO manufactures such abroad array of products it has theability to engineer precise solutionsthat provide smooth operational flowsfor customers. Having originally

tendered for the racking we were ableto offer Next the benefit of our capabilities to engineer a solution not

just for the racking but also for thepicking carts, shelving and packingtables, all meeting Nexts needsprecisely

requirements and then devising engineeredsolutions to suit. Next was looking for specificsolutions for the project and BITO investedtime in building various prototype trolleys.

BITO also supplied Next with equipmentfor 24 packaging locations. These are

formed from galvanised shelving, which pro-vides pigeon holes to place items for buildingcustomer orders, surrounding 2.2 x 1.2 mpacking tables. Each table is equipped withwaste bins, pull-out drawers, a computershelf and a monitor stand - everything that isneeded to pack efficiently.

Commenting on the installation, BITOsMD Edward Hutchison says: Because BITOmanufactures such a broad array of productsit has the ability to engineer precise solutionsthat provide smooth operational flows forcustomers. Having originally tendered for theracking we were able to offer Next the bene-fit of our capabilities to engineer a solutionnot just for the racking but also for the pick-ing carts, shelving and packing tables, allmeeting Nexts needs precisely.

www.bito.co.uk

With its head office and main productionfacilities in Germany, BITO is an interna-tionally operating manufacturer of storageand order picking systems. The companys

product range includes shelving and rack-ing; storage and order picking systems;bins and containers and warehouse equip-ment and accessories.

ABOUT BITO STORAGE SOLUTIONS


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18 Warehouse Floors


Warehouseflooringspecialists

The CoGri Group is passionateabout warehouse flooring

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Optimise oor performancein new-build or existing projects.

The CoGri Group global consortium is passionate aboutwarehouse flooring. They understand the principles behinda good quality floor whether it concerns new floors, floor

repairs or floor upgrades. They have a wealth of experience,knowledge and expertise which complement their understandingof the modern warehouse operation to provide the best solutionthat meets clients individual needs.

The CoGri Group was first established in 1989 as a smallmanual floor grinding company, operating single-headed, trol-ley-mounted grindingmachines. In the early 1990s, Mr. Dare inventedthe patented LaserGrinder to provide a bet-ter system of grinding floorssuperflat in operationalwarehouse aisles, with mini-

mum disruption to on-goingwarehouse operation. Atthe same time, his interestin floor flatness also led himto invest in the developmentof the FACE DigitalEquipment, used to meas-ure floor profiles.

Today, the CoGri Grouphas grown from its humblebeginning to a multinationalorganisation, with represen-tation worldwide operatingfrom their main offices in the United Kingdom, United ArabEmirates (UAE), Singapore, South Korea, China, Australia as wellas working with partners and agents across all continents. In

Asia, the CoGri Group is one of the leading floor contractorsoperating in the region and has a large share of the specialistindustrial floor construction market. To provide clients at homeand overseas with access to the best concrete flooring technolo-gy, a fleet of Laser Grinders, a family of FACE Digital floor flat-ness measuring devices and numerous advanced floor construc-tion equipment including Laser Screed floor constructionmachines are strategically stationed all over the world, with arecent addition of a Laser Screed permanently based in the UAE.

In their quest for flawless floors, the Group continues to inno-vate and constantly develop their flooring technology and systemsto allow them to meet the demands of the industry. They haverecently announced the launch of the next generation laser guidedconcrete floor grinding machine, the Laser Grinder XPT and theFACE All-in-one Profileograph, both of which are guaranteed to

achieve all international defined movement floor flatness specifica-tions. Their proactive approach to innovation, determination andcommitment means that they have been able to maintain theintegrity of their position as world leaders in their field.

www.cogrigroup.com


19/36


Warehouse Floors 19

Cutting edgetechnolgyC oncrete Grinding Ltd is delighted to announce the launch oftheir new Laser Grinder XPT, the next generation concretefloor grinding technology.

In todays fast paced world, customers can purchase items witha click of a mouse and select same day delivery. This means thatwarehouse operators are under pressure to perform at optimumefficiency 24/ 7 which leaves little room for error or downtime. AsMHE and warehouse technology becomes more sophisticated tocope with faster delivery and meet expectations, the demand forflatter floors has also grown.

The Laser Grinder XPT- Xtra Precision Technology, has beendeveloped to provide clients with a flatter floor than ever before.

As with its predecessor, the Laser Grinder XPT is suitable foroperation in a live warehouse environment, offering little or nodisruption to ongoing warehouse activities. Its ULTRAFLAT floorgrinding feature is amongst some of the Laser Grinder XPT newinnovations which include:- Curve computer control - allows minimal depth of grinding Reduced emissions which meets the latest Euro 5 standard Lower noiselevels < 80 DBA Enhanced

operator controlsystem Guaranteed toachieve all inter-national definedmovement speci-fications; TR34 &TR34 AppendixC, ACI Fmin,DIN 15185, EN15620 and

VDMA The new

Laser Grinder XPT has been under development and testing for over two yearswith plans for its first operation in March.

The original Laser Grinder was first invented in the early 1990s to accommodate the growing demand for an efficient andclean method of grinding concrete floors without disrupting theclients ongoing warehouse operation.

Concrete Grinding Ltd, a subsidiary of the global consortium,the CoGri Group, has been successfully upgrading new and exist-ing VNA/narrow aisle using the Laser Grinder for over 20 years.

Since then a fleet of 15 Laser Grinders have been built andare operating globally with a permanent base at ConcreteGrinding Ltds Head Office in the UK, Mainland Europe, MiddleEast, Singapore, Korea, China, and Australia.

With its strong R&D department, Concrete Grinding Ltd contin-ues to develop the Laser Grinder where the system gets finetuned and upgraded each time it returns to Head Office for main-tenance and servicing.

As experts and pioneers in their industry, Concrete Grinding Ltdis confident that the Laser Grinder XPT is a class above the restof the technology in existence today and it is the future of precisionconcrete flooring grinding in narrow aisles warehouses.

www.concrete-grinding.com

Concrete Grinding Limited are specialists in the enhancementof floor flatness, particularly in narrow aisles and havedeveloped the Laser Grinder , the Worlds most advancedlaser-guided grinding system. The Laser Grinder enablesaisles on new and existing floors to be upgraded to the flatnessstandards required to operate VNA forklift trucks safely and attheir optimum efficiency. Used in new and operationalwarehouses. It is clean, quick and very effective,while offering little disruption to the ongoingwarehouse activities.

Have yougot a

Flooring problem ...

www. concrete-grinding .com

Then call in the specialists

Making the World

a Flatter Place...

Concrete Grinding Ltd recentlyunveiled the Laser Grinder XPT


20/36

20 Warehouse Floors


Inadequate floors seriously reduce the efficiency ofwarehouse operations. Face Consultants have thespecialist expertise to optimise floor performancein new-build projects and existing premises.

Consultancy services include: Design

Mechanical handling efficiency Testing and diagnosis Repair proposals Due diligence and dilapidations

Call us for an initialno-obligation consultation

Flooring Advisory

Service ...

www. face-consultants .com

Boost yourwarehouseefciency andprotability Leading global warehouse flooring consultants, FaceConsultants Ltd (FACE) has completed a range of corporatevideos to raise awareness and provide a greater understand-

ing of its services.Photography and filming took place at various locations in the

UK. These productions, combined with footage taken at FACEHQ in Huddersfield, West Yorkshire, were used to create shortvideo clips About FACE and its floor testing services whichinclude Abrasion Resistance Testing, Slip Resistance Testing, FreeMovement Survey, Defined Movement Survey and Screed Testing.

Abrasion resistance is an important performance requirementin warehouses and industrial floors. Floors can be exposed toaggressive abrasions from trucks and hence it is important thatthey are able to resist wear on a daily basis. Tests are carried outusing their purpose designed and built equipment which conformsto the requirements of BS EN 13892-4: 2002. The depth ofwear is used to assess the quality of the floor and classifies thefloor in accordancewith BS 8204 2:2003.

Slip ResistanceTesting is carried out toassess the floors slippotential in a work-place and public areas

using the pendulumtest method. Floorscan be tested in-situ orflooring materi-als can be tested inour laboratory. Theslip resistance test that FACE offers uses the latest in pendulumtechnology to measure floors against relevant slip resistance stan-dards and guides.

Free movement surveys can be conducted where MaterialsHandling Equipment (MHE) have an infinite number of travelpaths. Free movement surveys are carried out to test if a floormeets appropriate flatness standards including property 1, 2 and4. Having a floor that meets free movement specification will ulti-mately result in a more efficient operation as MHE can movefaster and more smoothly over the surface.

Floors in very narrow aisle (VNA) racking systems have MHEthat runs in defined and fixed paths between the racking. Thehigher the racking, the flatter the floor needs to be. The floorsare measured with the FACE Digital Profileographs with slightly differing configurations. FACE can successfully report on afloors compliance to floor specifications based on the findings oftheir Defined Movement Surveys.

There are a range of Screed Tests available to ensure a ware-house floor is suitable for operation and / or floor covering appli-cation. Humidity screed testing can be carried out to determine ifthe screed is dry enough for resistant floor coverings. Pull OffTesting can also be conducted to test the bond strength of a sub-strate. Included in FACE range of screed testing services is DropTesting, also known as BRE Screed Testing which is used to testthat the performance of the screed is sound for service.

FACE hopes the videos will highlight the benefits of the servic-es available, have a positive impact on visitors experience andincrease visitors engagement.

FACE plans to build on its range of short films in the comingmonths and will be posting these on their website.

www.face-consultants.com

A new series of corporate videos raiseawareness of Face Consultants

Ltds flooring services

FACE on film


21/36


Warehouse Floors 21

CG Flooring Systems have recently completed a substantialjoint repair project at a warehouse in Milton Keynes for theBuilding and Property Consultancy Paragon LLP. Paragon

LLP were acting as the project manager on behalf of LaSalleInvestment Management and the warehouse occupier, an interna-tional high quality tyre company, and invited CG FlooringSystems to submit a proposal for the repair works.

The repairs were required on two expansion joints, each of 70metres in length running the entire width of the warehouse, main-ly in Free Movement (FM) Areas including a 35 metre sectionthrough the Very Narrow Aisle (VNA) Area of the warehouse. Therepair method carried out on both joints by a previous tenant hadfailed exhibiting signs of poor concrete compaction around themetal angles, excessive signs of premature wear and degradationonce subjected to operational traffic from the customers MaterialHandling Equipment (MHE). After a period of consultationbetween Paragon LLP and CG Flooring, agreement was reachedon an appropriate repair detail and a programme to execute therepair works.

With the emphasis on ensuring the joint repair works couldproceed with minimum impact to the customers ongoing opera-tions, the repairs were to take place over 4 phases treating halfthe length of each joint at a time. Based on good engineeringpractice the new repair detail involved cutting back to sound con-crete within the existing floor effectively forming a channel. Theold and damaged concrete was cut into blocks, which in turnwere lifted out and removed for disposal. This method ofremoval ensured a virtually dust free process without the need forerecting structures to prevent dust from contaminating warehousestock. The newly formed clean arris edges to the concrete slabsthen had holes drilled into them at regular intervals, into whichdowel bars were resin fixed in order to provide a load transfermechanism to prevent differential vertical movement at the joint,

which can be caused by the movement of MHE across the joint.Consolidation of the sub-base, application of a physical dampproof membrane and a layer of reinforcement mesh completedthe preparation works. An early strength, micro-silica concretewas then poured into the channel which received a power floatedfinish.

The project demanded a considered and measured approachin order to deliver the high standard of repair required, within anacceptable time frame. Each phase was completed over oneworking week and this could only be achieved by adopting adynamic approach with clear communication paths and undoubt-edly, an understanding warehouse occupier. The appointment ofa specialist industrial flooring contractor whose knowledge andunderstanding of not only concrete floors, but experience ofwarehouse operations to work in tandem with a thoroughly pro-fessional Project Management services and clear communicationby Paragon LLP, demonstrate in no small way the benefits of whatcan be achieved by using specialist Project Managers on chal-lenging projects.

www.cg-flooring.com

CG Flooring Systems, a leading specialist in itsfield, aims to provide the best solution for yourflooring needs. Our comprehensive rangeof services include:s Industrial pumped screedss Epoxy and resin coatingss Floor joint repairs

s Underlayments Surface preparationss Screeds for heated floor systems

Industrial Floor refurbishment ...

www. cg-ooring .com

Smoothing the Way

to Better Floors ...

Repairs or renewalwe have the answers...

s Floor joint stabilising

CG Flooring Systems have recentlycompleted a substantial joint repair project

at a warehouse in Milton Keynes

Specialistapproach to

joint repairs


22/36

22 Forklift Trucks


The Port of Bristol is Britains most cen-trally located deep sea port. With anestimated 42 million people living withina 250 km radius of the facility and theMidlands and London both within easy reach, it is recognised as one of the most

economical port distribution locations in theUK.

Plenty of major retailers and suppliers tothe retail sector have chosen to establishnational distribution centres near to the Portand one of the latest is leading wines andspirits importer Matthew Clark who recently moved into an 8,500 square metre storageunit within the Royal Portbury Dock part ofthe dock estate.

The facility is operated on Matthew Clarksbehalf by the Bristol Port Company and offers

over 10,000 pallet locations. While there is some block stacking at thesite, the majority of the pallets are storedwithin pallet racking served by a fleet of threeJungheinrich reach trucks.

The reach trucks - Jungheinrich ETV 320models with a 2-tonne capacity - were pur-chased outright by the Bristol Port Company.

A significant influence on the Bristol PortCompanys decision to specify models fromthe Jungheinrich range was the fact that thetrucks feature Jungheinrichs patented mastdampening system.

When working at height, truck masts sway and, for obvious safety reasons, truck opera-tors have to wait for the swaying to stopbefore attempting to deliver the pallet intothe racking. Jungheinrichs mast dampingsystem minimises elevated fork (laden orunladen) swaying time.

The pallet racking within Matthew Clarksfacility has been designed to maximize spaceavailable within the apex of the roof and, atits highest point, offers six beam levels. Thismeans that the trucks lift to heights of over

11.5 metres and it was calculated that theJungheinrich damping system saved 14 sec-onds per lift when compared to alternativemakes of reach truck.

Passing the Port test

The swtich to a fleet of three Jungheinrich reach trucks has enabled theBristol Port Company to improve efficiency at a port centric facility operated

on behalf of a leading wines and spirits importer


23/36


Forklift Trucks 23

The Bristol Port Companys Paul Osborne,who manages the Matthew Clark site, wasalso impressed by the trucks state of the art

AC technology which, importantly, ensuresthat running costs are kept to a minimum.

The trucks regenerative braking andregenerative mast lowering features reduceenergy usage and therefore truck runningcosts significantly by reclaiming excessenergy and using it to charge the battery every time operators brake or lower the forks.

Around 25 per cent of the energy neededduring a typical shift is reclaimed in this way meaning every fourth lift is energy free.

Some 4000 line items are stored atMatthew Clarks Bristol facility. Incoming lor-ries are unloaded using a combination ofpallet trucks and counterbalance machinesand pallets are checked and allocated aposition within the racking by MatthewClarkes warehouse management systembefore being put away by the reach trucks.

Because of the expensive and fragilenature of the loads and the heights to whichthey are lifted within the storage unit, each ofthe reach trucks is fitted with a fork-mounted

camera system, height selectors and cen-tralised side sift to ensure that pallet put-away and retrieval is as fast, efficient andsafe as possible.

We undertook numerous visits to ref-erence sites before concluding that ourclients needs were best met by theJungheinrich trucks, reflects PaulOsborne.

We also involved our drivers in thedecision and they were impressed by thetrucks handling and the comfortableworking environment that they offer.

The trucks were supplied with a redpaint finish to meet The Bristol PortCompanys corporate requirements.

www.jungheinrich.co.uk

We undertook numerous visits toreference sites before concluding thatour clients needs were best met bythe Jungheinrich trucks. We alsoinvolved our drivers in the decisionand they were impressed by thecomfort that the trucks offer

AT AGLANCE

USER: BristolPort CompanyINDUSTRYSECTORSERVED:Logistics ServicesEQUIPMENTSUPPLIER:Jungheinrich UKLtd

ROI: Greater space utilisationand faster throughput speeds

Jungheinrich have announced the launch of newadditions to their ranges of ic-engine and electric-powered counterbalanced forklift trucks.Both the electric and engine trucks have been

designed to offer the highest standards of energy effi-ciency, throughput performance and operator comfort.

VFG Series 5sThe ic-engine model the VFG Series 5s is available

in both diesel and LP Gas options.The trucks are powered by a Volkswagen engine and

have a capacity of up to 5.00 tonnes.Like other trucks in the Jungheinrich range of ic-

engine counterbalance forklifts, the VFG Series 5s fea-tures hydrostatic drive technology.

Compared with the traditional torque convertertype of transmission system used in counterbalancedtrucks, hydrostatic drive technology has fewer mechani-cal components and, as a result, requires less routinemaintenance. The technology is also easy to work on.

The hydrostatic drive technology ensures low exhaust

emissions. The Jungheinrich VFG Series 5ss emissions

are the lowest in their class and well below the limitrequired by the new EU IIIB legislation that is due tocome into effect from 2013 and will see the legal limitfor exhaust soot particles reduced by 95 per cent.

Noise and vibration levels are also minimal. When it comes to fuel efficiency, independent tests

have demonstrated that hydrostatic trucks consume 2litres of diesel or 2kg of gas less per hour than torqueconverter driven alternative.

The VFG Series 5s offers high levels of productivity.The engine speed automatically increases during thelifting process and all mast functions, truck accelerationand braking and changes of direction are smooth andprecise.

To further enhance handling performance and tomaximize energy saving, five different operating pro-grammes allow the driver to set the trucks performancecharacteristics to match the load and the operatingenvironment.

We believe that with its combination of low energy consumption and operating costs and ultra low exhaust

Continued on page 24

New engine and electriccounterbalanced models


24/36

24 Forklift Trucks


emissions, the VFG Series 5s sets a newbenchmark in ic-engine counterbalance truckdesign, says Craig Johnson, marketingmanager of Jungheinrich UK Ltd.

He adds: Not only is the truck the clean-est in its class, the hydrostatic technology requires between 20 and 30 per cent lessfuel compared to the market average. Thismeans less environmental impact and higherproductivity.

EFG 425-430Jungheinrichs new electric counterbalancedtruck the EFG Series 4 has a load capaci-ty of up to 3.00 tonnes The new model is

available with a choice of chassis lengths including a short chassis version that reducesthe trucks turning circle.

Like other electric-powered trucks in theJungheinrich range of materials handlingequipment, the EFG 425-430 models featurefourth generation AC technology.

Highly environmentally friendly,Jungheinrichs latest AC technology givestrucks an exceptional efficiency ratio andconstantly low energy consumption. In fact,tests have shown that the new EFG Series 4

trucks are 10 per cent more energy efficienctthan the models they replace.The low energy costs are further reduced

through energy reclamation during braking,so that a battery change inmost applications over twoshifts is no longer necessary.

Fourth generation technolo-gy also offers productivity ben-efits as it enables trucks toaccelerate far more quickly than less advanced systems enabling more loads to bemoved per shift.

When it comes to battery changing, a new device allowsthe battery to be removed easily,quickly and safely. The SnapFitadaptor is a mechanism fitted to astandard pallet truck that locks into the underside of a 48 or80 Volt battery effortlessly.The self guided SnapFitbattery changing devicereduces the time it

takes to

secure and remove a battery when it is duefor recharging considerably.

For the truck operator, the new EFG Series4 features a number of design ideas thatallow the operator to adjust his working posi-tion to maximize comfort. The trucks slimsteering column, intuitive seat and seatmounted armrest also improve the operatorssense of well being and therefore stay fatiguefree over the course of a shift .

The cab itself is spacious with an openand uncluttered floor area and, when itcomes to forward visibility, the EFG Series 4smast is 50mm wider than the model itreplaces while the trucks overhead safety

guard offers a virtually completely unob-structed view.

A number of safety features have alsobeen introduced to the new Series 4 as stan-dard. For example, the trucks all featureJungheinrichs Curve Control which automati-cally reduces the trucks drive speed as itenters a corner by monitoring the trucksspeed, wheel position and steering angle.

At the heart of the Curve Control system isa continuously working sensing unit thatmonitors the trucks steering angle. Simply

stated, the system quickly and effectively reduces the drive speed when an excessivesteering angle is sensed.Jungheinrich claimthat trucks fitted with Curve Control offer

marketleadingstability

Jungheinrich UKLtd offers PalletTrucks,Stackers,Counterbalanceand ReachTrucks, Order Pickers, VNA

and Stacker Cranes in morethan 600 vari-ants. As well asthis, thecompanyprovides anextensive

AftersalesSupportNetwork, Rentaland FinancialServices,

RackingSystems andWarehousePlanning.

ABOUTJUNGHEINRICHUK LTD


25/36

Lithium-ion:Now a RealityThe only specically designed Lithium-ion Powered Pallet Truck on the marketFor further information please call 0800 357 457

www.jungheinrich.co.uk


26/36

26 Warehouse Management Systems


In just 15 years, Great Bear has become asignificant player in the UK Logistics market.Managing over 3 million square feet of ware-housing, 23 distribution centres, 150 vehiclesand 1,200 people, Great Bear today turnsover more than 85 million. Blending thebest of entrepreneurial innovation and thecustomer focus of the smaller organisationwith the scope and reach of a corporate,Great Bear runs a true multi-site, multi-client3PL operation for a range of clients in thegrocery, manufacturing and retail marketsthat include household names likeSainsburys, Mars, Umbro, Unilever andMichelin.

With logistics solutions in the ambient,multi-user and chilled sectors, Great Bearalso provides its customers with a range ofshared resources, services and facilities. Theprimary focus of these operations is full loadtraffic, using both dedicated resources andregional partners to deliver rate per load

traffic nationally and includes value addedre-working services.Technology infrastructure is critically

important to Great Bear, underpinning its

Adding3PL valueto thesupply

chainability to deliver a fast, accurate, flexible andhighly cost-efficient service. At the heart ofthat infrastructure is Autostore, one ofEuropes leading enterprise warehouse man-agement and control solutions. Developed by supply chain software specialists CentralSystems & Automation, Autostore is GreatBears key to delivering future-proofed valueand high performance supply chain manage-ment for its customers.

Great Bear and Central Systems & Automation combine to offer a package ofcredibility, performance, functionality andprice that has helped put Great Bear on aperformance par with larger 3PLs. The rela-tionship proves how complementary busi-nesses can work together to add a level ofvalue in tough trading conditions that strike aprofound chord with the market.

Tuning the 3PL model fortough timesToday, customers are seeking lower inventory with higher throughput at a lower operatingcost coupled with the ability to consolidateand scale their supply chain operations for

Autostore from CentralSystems and

Automation is allowingGreat Bear to offer aproven 3PL model that deliv-ers a level of supply chainvalue and performance thatsdifficult to match

AT AGLANCEUSER: GreatBear INDUSTRYSECTORSERVED:Logistics servicesEQUIPMENTSUPPLIER:Central Systems& AutomationRETURN ONINVESTMENT:Lower operatingcosts and greater client flexibility


27/36


Warehouse Management Systems 27

changes in demand and future growth.Outsourced 3PL supply chain managementhas two key focus points asset manage-ment and information management. Its thesoftware technology that innovative 3PLs likeGreat Bear are using to drive integrated andexpanded service offerings that increase rev-enues and drive exceptional value and thisis where the Autostore enterprise WMS soft-ware solution comes in.

The flexibility to handle ebbs and flows indemand across sites and multiple customersin real time is critical: it removesinbound/outbound delays, costly customisa-tion as well as tricky integration and highersystems maintenance costs. The supply chainis a clear source of competitive advantage andGreat Bears clients view the company as a nat-ural extension of their core operations, able toplace a constant downward pressure on costswhile being able to respond instantly to changesin market demand for product. Great Bear now

uses Autostore to deliver this fingertip flexibility across several of its distribution centres forblue-chip clients like Cadburys, PremierFoods and Mars.

Embedding best practice at theDesborough DCGreat Bears newest distribution centre atDesborough in Northamptonshire is a text-book example of 21st century supply chainmanagement thats as flexible as it is efficient.Built in 2007 and completed inside 12months, the green-field Desborough

Distribution Centre (DDC) covers 475,000 sqft of storage space with 70,000 pallet posi-tions in four chambers - plus 58 loading bayswith four level access doors and four auto-mated vehicle off load bays. DDC comprisesfour main chambers with 35,000 pallets inthe temperature managed chamber; 8,000pallets over 1,200 pick faces in the high vol-ume case pick zone; 5,000 pallets in the chillchamber; and 22,000 pallets in the nor-malised ambient chamber. DDC has helpedone Great Bear client to consolidate its multi-

ple format UK supply chain operations fromthree sites to two.On peak days, DDC will handle around

3,400 pallets inbound and 4,000 outbound,comprising 105,000 case picks across 300orders and up to 275 vehicles. Autostore isnetworked across the site, co-ordinating andscheduling all stock movements in real-time.

It communicates with all mechanical han-dling equipment (MHE) across radio frequen-cy (RF) terminals and the RF system carries thedata for receipt of goods, pallet storage andretrieval, marshalling, loading, case picking,rework and added value services and yardmanagement data. Radio data terminals(RDT) give Great Bears users complete free-dom around DDC and means that more pal-lets can be handled faster and more accu-rately at least cost. Because Autostore worksin real time, it gives Great Bear instant andfull visibility and control over every item ofstock held: where it has come from, where itis located and when and where it is going.

The benefits of standardisationMark Roberts is Great Bears GeneralManager, Business Development: The sys-tems, hardware and software are an integralpart of how we designed Desborough. We

The RFID system provides control of the truck at the ends of the aisle, giv-ing the operator greater confidence inoperating at a higher speed when inthe aisle


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28 Warehouse Management Systems


take a factory-style approach that is alwaysto look forward and keep the flow of goodsmoving: we pick ahead and pre-assemble.

Autostore is already a proven solution for us- prioritising and managing daily workflowsat several sites and across multiple clients.This level of strategic standardisation gives usthe operational flexibility we need plus thepredictability and performance we need tobe able to deliver reliability and efficiency forour clients. Its a trust thing: not only does

Autostore fit us well, theres a strong culturalfit between our two organisations that hasevolved into a true business partnership.

A major benefit of this standardisation is

the simple integration between Autostore andour clients enterprise resource planning(ERP) systems. No two Great Bear clients arethe same and the fundamental key to deliv-ering an effective supply chain solution isclarity and timeliness of the mission-criticalinformation - and the ability to act on itquickly and without error, he added.

Standardisation on a single, multi-site WMS makes clear practical sense. But why Autostore? Andrew McKaig is commercialdirector at Central Systems & Automation:

Perhaps the most important single consider-ation is confidence in the system you choose.It has to work from the off and deliver notonly against the specification but be robustenough to handle the unexpected too.

Autostore has been proven over many yearsand in many organisations to deliver exactly that level of power and reliability - rightacross the automated, manual and mixedwarehouse spectrum.

Whether operators are in the warehouseor making decisions in the boardroom,

Autostores flexible and fast reporting capa-bilities mean that everyone gets the informa-tion they need in the format they want, whenthey want it. Theres no time-consuming dou-ble keying of data, just a simultaneous, real-time picture of whats happening andwhats required, he added.

Taking a balanced approachFrom a technical perspective, Great Bearsembracing of leading-edge and standardisedIT infrastructure at DDC and other sitesmeans it can precisely match client demands

without costly integration issues. Pallet andgoods processing is faster, enabling GreatBear to make Desborough work closer to itscapacity limits without compromising per-

formance or the need for physical expansion.Plus, the centralised control of data ensuresthat network bandwidth is optimised, making

for a leaner and more efficient technology backbone.

Its no surprise that the shared benefitsand shared objectives that drive Great Bearand Central Systems & Automation havestruck a chord with some of the UK bestknown brands. Using a light touch supply chain management model thats nimble, flex-ible and effective, Great Bear today offersintegrated, technology-driven solutions thatcombine the gravitas of a major player with-out losing site of the companys entrepre-

neurial, customer-focused roots.Rick Geall is Great Bears OperationsDirector for the South of England: Ourextensive investment in technology doesntlock us into purely automated warehousingand supply chain management solutions. AtDesborough we run a mixed range of peopleand technology-led processes that offer abalanced approach for least cost today andflexibility tomorrow. It cuts inventory holdings,increases throughput and delivers real valueto our clients. As a custodian to our clientsbrands, our ability to manage and handletheir stock to exceptional levels of accuracy allows them to focus on their core competen-cies - knowing that when they call on theirstock, it will be there, in the right conditionand in the right quantities.

Our IT systems and Autostore in partic-ular provide us with a high level of sophisti-cation but without the complexity that oftenmeans a high total cost of ownership. At atime when efficiency and profitability havenever been more important to our clients andUK businesses as a whole, we can offer a

proven 3PL model that delivers a level ofvalue, performance and edge in the supply chain thats difficult to match by our competi-tors, finished Geall.

Founded in1988, CentralSystems &

Automation Ltdis one of Europes leadingsoftware devel-opment and inte-gration compa-nies for th inter-modal and logis-tics industries.The companyhas a wide net-work of partnersthroughout theEU and MiddleEast

ABOUTCENTRAL

SYSTEMS &AUTOMATION


29/36

ALL THE CONTROL YOUNEED IN ONE WAREHOUSEMANAGEMENT SYSTEM

AUTOMATION | PICKING | MARSHALLING | STORAGE | JIT | DELIVERY | WEB-ENABLEDMANAGEMENT | ACCURACY | CONNECTIVITY | SECURITY | PROFITABILITY

CENTRAL SYSTEMS & AUTOMATION LTD2 THORPE WAY, GROVE BUSINESS PARK ENDERBY, LEICESTER, LE19 1SUUNITED KINGDOM

Tel: +44 (0)116 282 1800Fax: +44 (0)116 282 1801Email: [email protected]

Web: www.central-systems.co.uk

Autostore is a single, state-of-the-art warehouse management solutiondeveloped specically for the supply chain and logistics industries. Itenables you to manage all types and all sizes of goods into and out of

your distribution centres or warehouses whether they are automated,manual or mixed. With Autostore, your goods will be in the right place, with the right people, in the right quantity at the right time every time.

Integrating seamlessly with your existing or legacy systems, it deliverssecure, precise and exible warehouse management from pick to pallet,from marshalling yard to boardroom. Autostore is proven internationally and across the UK to enhance productivity, efciency and mostimportantly, protability.


30/36

30 Loading Bays


As a true one-stop-shop for loading baysand industrial doors, Hrmann are ideally placed to deliver the best solutions for allloading bay requirements. From doors totraffic control systems, Hrmann has theproducts and flexibility to meet the specificdemands of any logistics operator. Withintegration at the core of the developmentprocess, dock levellers, door shelters, and

ancillary equipment work togetherseamlessly, helping improve both efficiency and safety.

With pressure on for supply chains todeliver savings and efficiencies, good loadingbay design can deliver both. For Hrmanngood planning is the key. By consideringfuture use, as well as current need, sitegeography and consistency with other sites,Hrmann are able to maximise both safety and operational efficiency.

For example, the first consideration whenplanning loading bays is the type and size of

vehicles likely to be operated. For the RoyalMail this is a particular challenge due to thelarge variety of vehicle types they need toaccept. When designed, the loading bays atSwan Valley distribution centre inNorthampton both the current fleet andpotential vehicle developments whereconsidered. To help manage his diversity Hormann manufactured non-standard heavy duty dock levellers and bespoke dockshelters.

Once the type of vehicles operated isaccounted for, site geography then plays it

part with the direction of vehicle movements,turning space and site safety all importantfactors. For the Co-operative at Newhouseangled loading bays where recommended ,for the ambient section, to maximise

Hrmans are ideally placedto deliver the best solutions

for all loading bayrequirements.

available space. When a basic layout is confirmed, then

the attention focusses on specific needs ofthe operation. For Teva Pharmaceuticals,being able to dock their trucks withoutopening the rear doors was a key requirement. Hrmann installed the DOBOsystem that was originally designed for coldchain operations. The system allows a vehicleto dock on the bay before the inflatable dockseals surround the vehicle. When sealed theloading bay door is opened and the truckdoors can be unlocked and opened into therecess designed behind the door.

The rising cost of fuel and attention toenvironmental impact has made thermalefficiency a key feature, particularly for newbuilds. For Asda, Hrmann introduced highspeed spiral doors or the level access bays attheir Didcot distribution centre. These doorsreplace the traditional two door solution of ahigh speed curtain door for daytime use, witha sectional outer door for night-time security.External consultants working for Asdaestimated the energy cost savings achievedwith this solution would pay for the doorswithin two years.

As energy efficiency continues to be amajor factor, options previously developedfor cold storage operations are now beingapplied to ambient warehouses. Theexpertise that Hrmann has gained inworking with cold store specialists, ISD ColdStores, on specific solutions is keeping thecompany at the fore front of newdevelopments.

Whatever your requirement Hrmann hasthe knowledge, expertise and products toproduce the right solutions to meetoperational and budgetary constraints.

Loading

Bays


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Lockwell + Eco Projects have implemented energy effi-ciency lighting projects at Midlands based tile manu-facturer, Johnson Tiles, which are saving enough ener-gy to boil over 4 million cups of tea every year? An ini-tial project within the Very Narrow Aisle warehouse, isbeing followed by office, production and other ware-

house areas. The combined projects are deliveringaround 1,010,000 kWh per annum.

Last year leading electrical distributors and whole-salers, Lockwell, joined forces with manufacturers ofadvanced energy efficient lighting products; PremiumLighting Solutions (PLS) and Altoeco, under their EcoProjects alliance, to deliver a turn-key solution to facethe challenges of reducing warehouse, industrial andcommercial energy costs.

With the rising costs associated with lighting, ware-house owners and managers are increasingly turningtheir attention towards the most effective methods of

reducing their energy consumption.Current estimates suggest that lighting within awarehouse environment accounts for in excess of 70%of the total energy usage. With average savings in thisarea ranging from 60-80%, talk of energy-saving light-ing cannot be ignored.

The Lockwell + Eco Projects partnership not only delivers savings and improvements in the warehouse,but also in offices, flood lighting and other areas.

Lockwell + Eco Projects lighting systems delivenough energy to boil over 4 million cups oftea each year at Johnson Tiles alone

In the lighting marketplace where there are many potential purchasing options, it is not good enough toselect a product based purely on its energy-saving mer-its. The starting point for any retro-fit solution must bethe provision of the right lighting level, lighting quality and potential maintenance costs. It is no good to savehalf the energy, if light levels are also halved, or the

existing shadowing is replicated. Conventional light fit-tings have inherent problems, which are not necessarily addressed by some solutions being implemented withinindustrial and warehousing facilities.

"Anyone can sell lighting but what I likedwas the fact that with Eco Projects you getthe whole package products, delivery,installation, warranty and an entire

knowledgeable teamJason Bridges, Engineering Buyer,Johnson Tiles

Saving energyis not enoughThe entire process of purchasing, deliveringand installing our new lighting was easy andefficient. The health and safety and generalenvironment was great and the installationsteam were professional and tidy. Im reallyhappy with the final product and highly

recommend this lighting range to othercompaniesMike Keen - Engineering Manager

32 Lighting Management



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It takes time to identify where energy is being lost, toassess the increasingly high numbers of alternatives, to

calculate the potential savings of one fitting over anoth-er A challenge Lockwell Technical Director, MarkBailey understands all to well,

We understand that it is not a lack of will, but timeand a lack of specialist knowledge in this area thatleads to delays. Our aim is to provide clients with asimple solution which takes their need from the initialauditing stages right through to handling any ongoingsupport and maintenance following installation.

The partnership between Lockwell and Eco Projectsbrings together the abilities of both companies to pro-vide: Initial energy audits Identifying tax savings Detailing Carbon Trust or Pay-As-You-SaveLease opportunities including assisting applications Bespoke lighting designs Full data logging services Project management at a local level Installation, Method Statements and Risk

Assessments Ongoing support of the solution Local contacts with 22 Lockwell branches through-out the UK

Eurocell plc has established an enviable reputationfor its precision extrusion capabilities and PVC-U prod-uct innovations. The company operates from a pur-

A perfect partnership

projects

In short, the Lockwell & Eco Projects team provides acomplete solution from start to finish. The cost of delay-

ing a project is more than you might think, so get intouch with our team today to see how we can help yourproject become a reality. Call 0845 272 5265 or [email protected]

The time involved in identifying andimplementing energy saving solutions is oftena major factor in warehouse managers failingto move forward with cost savingalternatives

pose-built 80,000 sq. ft extrusion and tool-making facil-ity, with more than 260,000 sq. ft of stockholdingcapacity, employing around 1,000 people nationwide.

An intensive audit of the production facility s currentlighting by Lockwell & Eco Projects highlighted some key areas for energy efficiency savings when compared tothe out-dated inefficent luminaires. Not only was thequality of light very poor, but the maintenance costswere mounting as lamp failures occured on a regularbasis.

Since our installation of 60 intelligent luminaires inthe production facility, light levels have improved dra-matically; energy usage and electricity costs have morethan halved and CO2 savings go a long way to meet-ing group policy targets, as well as ISO 14001:2004accreditation commitments.

Lighting Management 33



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34 UKWA Awards


The United Kingdom Warehousing Association (UKWA) recognises BestPractice in the third party logistics (3PL)sector at its Annual Awards for Warehousingceremony.

Held at Londons Dorchester Hotel, theUKWA Awards for Warehousing Luncheon isfirmly established as one of the most popularoccasions in the 3PL calendar and is rightly regarded as an excellent networking opportu-nity. Last year, nearly 500 UKWA membersand their guests attended the event.

This year, the Awards ceremony - which issponsored by Jungheinrich UK - takesplace on Wednesday 4th July and a total ofnine awards will be presented. They are: Customer Service Award

Awarded to a 3PL provider that can demon-strate high levels of customer insight and acustomer focused culture; Training AwardThis award - which can be awarded to anindividual, organisation or jointly to both - isgiven for training achievement; Best New Warehouse Member

A corporate award given to the company showing the highest professional standards ofwarehousing on joining UKWA;

Warehouse Manager of the Year AwardPresented to a warehouse or distribution cen-tre manager who shows excellent personal

Recognisingexcellence inthe logisticsindustry

Each year, the United KingdomWarehousing Association recognises Best

Practice in the third party logistics sector ata prestigious Awards ceremony at LondonsDorchester Hotel

and professional qualities which are reflectedin an efficient operation, optimum ware-house productivity, and a highly motivatedand flexible team; Team of the YearThis award goes to a company or depot that isable to demonstrate an outstanding team effortin their warehousing operations that has result-ed, or will result, in greater productivity and/orincreased profit.; Technology/Innovations AwardPresented to a supplier of a product or servicethat shows a bold and innovative response tothe ever-changing logistics and supply chainmarket place; Young Employee of the YearNew for 2012, this Award is open to any employee under the age of 25. The winnerwill be an excellent role model who hasalready produced encouraging results thatindicate a bright future; Environment AwardThe UKWA Environment Award is given tothe company that demonstrates the most sig-

nificant and successful application of greenprocesses, procedures or monitoring duringthe year; Chairmans Award


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UKWA Awards 35

The Chairmans Award is, as its name sug-gests, awarded by UKWAs Chairman to anindividual or company who has made a realand lasting contribution to the warehousingindustry.

Winners of last years Awards included ExpectDistribution who collected the Team Of TheYear and the Customer Service awards.Operations Director Neil Rushworth was under-standably delighted with his companys success:"I was particularly pleased to win the CustomerService Award as I believe that it demonstratedour commitment to our customers, he said.

"It was a fantastic achievement to berecognised as the best in the UK, but to do itin two categories was unbelievable. Winningthe Awards gave everyone in the company atremendous boost.

Toyota Tsusho UK Ltd won the keenly contested Best New UK Member Award in2011. The company joined UKWA in 2010and inspector Richard Davies was duly impressed with the extensive range of servicesthe company offers from its purpose built

facility at Castle Donnington.Winning the Award was marvellous,commented Toyota Tsushos log ist ics man -ager, Richard Frisby. The day after the

Prices and booking detailsLast year nearly 500 UKWA members and their guestsattended the Awards for Warehousing Luncheon. If

youd like to join them in celerbating the achievementsof others in the industry a table of 12 can be reservedfor 1090.00plus VAT while individual places can bebooked at 99.00 plus VAT.

The event commences at 12 noon with a GalaReception in the Opal Suite followed by a 3-courseluncheon. The days events finish between 3.45 and4.00pm and the dress code is lounge suits. Tickets canbe bought by cheque or credit card. Please contact

Jacquie Corderoy on (tel) 0207 836 5522 for furtherdetails.

Awar ds lu nc h, we go t al l the teamtogether and gave e veryone a pat on theback. It had a tremendously positive motiva-tional effect.

Another double award winner in 2011 wasCentury Logistics . The companys Paul

Wilson collected the Warehouse Manager ofthe Year Award while Century team supervisorDes Bailey was announced as the Employee ofthe Year.

Winning the two Awards helped raise ourprofile in the sector considerably, said thecompanys MD Stephen Basey-Fisher.

The Awards lunch itself is always an excel-lent day. We make a point of entertaining

clients at the event and it is a great opportuni-ty to show them our industry at its very best.

Meanwhile, Elddis Transport beat offtough competition to win the Environmental

Award in recognition for their on-going car-bon reduction programmes.

The award illustrated our on-going com-mitment to reducing our carbon footprint andimpact on the environment, said tNigelCook, MD of Elddis.

Nigel Cook added: It was a tremendoushonour to win a national award and the pres-

tige that comes with an UKWA Awardallowsed us to send out some very positivemessages about our business and the way weoperate.

UKWA chief executive officer, Roger Williams, comments: UKWAs Awards areestablished as symbols of achievement in the3PL sector and emphasise the importance oflogistics within todays economy. The highnumber and quality of the entries we receivedunderlines the professionalism that runsthrough the modern logistics industry.

ABOVE: Last years UKWA Awards win-ners gatheron stage atTheDorchester


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Need LegalAdvice?

UKWA members have access to a FREE legal advice helpline

UKWAs Honorary Legal Advisers - Aaron & Partners LLP - are happy todiscuss a wide range of business related legal issues from contract

disputes to exercising a lien

Call 01244 405577 for a free consultation

For further details of this and other UKWA member services,l t t Mi h

Documents

Warehouse Best Practices