The drive is on to fully integrate material handling into the enterprise, through lean/flexible manufacturing; RFID technology; Supply Chain, Warehouse Management System (WMS), and other software; and enhanced products and technologies.
This sector has been transformed, at both its simplest and most complex. Notes Chris York, principal of Tompkins Associates: "There is work underway right now to integrate SCADA and process control systems over an IP network to automatic data capture and messaging middleware that will open up granular visibility and control down to the shop floor level -- Many manufacturers can benefit from wireless data capture on the factory floor -- this can be used for time entry, shop floor manufacturing order completion, material moves, maintenance, and MRO inventory issue and delivery." (For more, click here.)
Returnable plastic containers have experienced a technology evolution, according to Eric Fredrickson, sales and marketing manager at IPL Products Ltd, with collapsible design reducing return freight costs and improved tracking and control. "We are seeing great synergy between manufacturers' and retailers' needs for supply chain visibility," says Fredrickson. "If a container has a permanent license plate, whether it be a smart RFID tag or a barcode label, information about what is in the container, where it is, where it has been, and where it is going, etc. can be associated with the license plate in a database." (For more, click here.)
Material handling systems will have to provide more flexibility and greater uptime in the future. "This means equipment will be required to adapt to frequently changing production configurations," says Steve Albert, gm of Presto Lifts Inc. Ergonomic considerations cannot be ignored, either, since "most companies will not tolerate the disruptions resulting from the injuries that come from poorly designed work processes," Albert notes. Powered lift tables and stackers will limit worker fatigue and injury. (For more, click here.)
Kevin Kozuszek, marketing manager at FKI Logistex's Alvey Systems, believes that order accuracy and storage reduction are big challenges as well. Software can address the former. As for inventory control, "facilities will need to implement JIT, or buffer storage situations." Kozuszek believes that "carousels coupled with IE devices or PTL" can help solve storage problems. (For more, click here.)
When Doubling Isn't Enough
"Many organizations put in basic inventory management software and in some cases pick to light technology, but those steps can only double efficiencies at best," contends Ed Romaine, Remstar International's director of marketing and e-commerce business development. Efficiency improvements of 300-600% "are needed to help reach corporate business objectives," Romaine continues. "This type of increase can be found using existing technologies such as horizontal and vertical carousels and VLMs utilizing pick-to-light technologies and inventory management software." (For more, click here.)
John Pelka, vp of sales and marketing at FKI Logistex, sees advances on the equipment and software side. Conveyor and sortation speeds are accelerating sharply, with added accuracy. Pelka points to such innovations as the ES3000 tilt tray sorter, "which actually banks into turns, allowing for faster speeds and more accurate placement." Even greater strides can be expected in software, he contends. For example, FKIL is developing the Logistex Software Suite (LSS), which "will provide customers with a complete SW and control solution based on a set of off-the-shelf modules and applications with only minor customization." (For more, click here.)
E-manufacturing has shown the material handling sector how to link software and communications for greater efficiency, comments Pelka. "Traditionally the material handling community moves slowly when evaluating change due to the high costs associated with it, but the technology and bottom line efficiencies associated with e-manufacturing are allowing companies that are taking smart, calculated steps in implementing these concepts to see solid operational gains and advantages over their competition," he notes.
Going Wireless
"Operating efficiency and cutting costs are two of the major concerns that the material handling sector is faced with on a daily basis," believes Richard Bauly, vp of strategy and business development at Psion Teklogix. "In this industry there is very little room for error; tasks need to be completed once and done right. The advances in wireless technology and 802.11b standards are having a profound impact on the material handling sector by allowing data to be collected and transferred in real-time from the warehouse floor."
Security issues may not pose a major obstacle to the use of such applications. "WLAN systems when properly deployed and using WEP security standards are secure," Bauly explains. "Security standards are continually evolving, and the 802.1x security standard will soon be accepted in the market and will further strengthen WLAN security." (For more, click here.)
Pelka agrees: "Wireless technology, including RFID, is encrypted to maintain data security and integrity. Also, during the initial write process, the data is written on the tag and to the database, which are matched when read. This also improves security."
Faith in wireless security is by no means universal. Tompkins Associates' York tells IEN: "In general wireless networks are not that secure and you seem to have two camps in the marketplace -- companies who will not allow wireless devices on the network and those that see such productivity improvements that they decide it is worth the risk. There have been some good proprietary options delivered by companies like Symbol Technologies and Cisco Systems, while others have put their wireless access points outside their network and connected them through a VPN so that it reduces the risk of network penetration and wireless snooping. There are VPN clients available for wireless devices that have gotten good reviews, but I wouldn't expect the transmission protocol standard to incorporate great security for some time to come."
More Software Everywhere
Simulations help companies more effectively plan their use of AGVs, observes Ryan S. Willis, director of marketing and business development at Transbotics. Its emulations -- small-scale simulations -- use actual software and hardware from the company's vehicles and systems, and look at blocking, charging, speed, and load-handling factors. Additionally, Transbotics introduced quad steer capability as an AGV option that allows its vehicles to change direction and/or steering mode at any time.
And Bunting Magnetics turned to 3-D modeling to develop its beltless MagSlide chip and parts conveyor line. The conveyors handle abrasive parts and scrap with high-energy ceramic or rare earth magnets moved by permanently lubricated drive chains. (For more, click here.)
The future will also bring mobile computing to material handling, according to Bauly. "The next step will be to bring the power of a desktop computer onto the warehouse floor but packaged in a rugged mobile form factor that lets workers complete their specific tasks," he tells IEN. "By providing this power in a mobile form factor, the material handling sector can move beyond just collecting and transferring data to completing inspections, quality control tests and examining worker productivity from the warehouse floor," Bauly predicts.
"We see further integration of every element in the supply chain to create efficiencies that minimize packaging material waste, reduce labor dependence, speed loading and unloading operations and ultimately reduce the impact of shipping and handling on the bottom line," notes Jack Pape, vp sales and marketing, Meese Orbitron Dunne Co. He tells IEN that reusable containers "are easier to clean than ever," with improved tracking systems allowing more companies to manage their own fleets. The containers of the future "may feature permanent, molded-in codes as standard," leading to completely integrated inventory management systems. (For more, click here.)
Software is tackling another key material handling issue -- waste. Syspro Group's Material Yield System lets cut-shape suppliers "return scraps to inventory and automatically determine whether future orders can be filled from the scraps," says Joey Benadretti, vp of Syspro Americas. "Most enterprise resource planning (ERP) systems deliver generic applications but fail to offer any that maximize the use of remnants," Benadretti contends. (For more, click here.)
According to Sil Zoratti, business development manager at Invensys Avantis, the trend toward lean manufacturing means "assets and knowledge about asset health are becoming vital." Such products as the Avantis Enterprise Asset Management (EAM) real-time system can provide maintenance and operation staff "with crucial information about all important assets to support the integrated enterprise," says Zoratti.
Many small and mid-sized companies have purchased WMS software to integrate material handling with the legacy parts of their facilities. But most WMS software focuses in inbound functions, states Tom Lagaly, vp of sales and marketing at FKI Logistex Real Time Solutions, and costly modifications are required to integrated outbound automation. One solution is to "implement a non-inventory based component to the existing framework that will bridge the gap between materials handling technology and existing/legacy WMS or ERP systems," Lagaly tells IEN. For example, FKI Logistex Real Time Solutions' OPS software modules interface with existing WMS or ERP systems "without requiring any additional software modifications." (For more, click here.)
