IEN: How do MH vendors handle lean/agile mandates?
Brittingham: These management approaches are in one way or another based upon workflow and achieving ways of maximizing it. Nothing can put a greater pinch on the stream of products working its way through the facility than the dock. The whole process begins and ends there, and if downtime happens due to equipment failures, poorly specified equipment, or dock accidents, it all ripples from there.
Choosing the equipment that comprises the dock can have a significant effect on processes both up and downstream:
- Doors -- Can they withstand being battered and clipped by forklifts? Dock doors are common victims of speeding forklifts, and taking out even one door in a facility with scores of openings can mean headaches in rerouting the traffic pattern and arriving trucks to other doorways.
- Levelers -- Does the deck walk down easily to save time after the truck is loaded/unloaded? The leveler should be designed to withstand the number of cycles it needs to perform during the day. Can the leveler handle wide loads if necessary, deal with varying truck heights, or operate without interfering with the trailer?
- Restraints -- Are trucks able to leave the dock easily? Can the restraint handle different size trucks and varying ICC bar heights?
In addition, we recognize that for this flow to occur smoothly, we need to be concerned about what takes place beyond the dock. SPX Dock Products conducts seminars for architects involved with commercial and industrial projects on optimal dock design such as where to place the dock, traffic flow considerations, the apron space outside the building, and types of dock such as saw tooth, pier, and freestanding docks.
In the past, docks were probably one of the last areas of consideration in the scope of the overall building project. The realization that the buildup of pallets in the dock area can mean the rest of the operation is being held up makes docks very much part of the lean manufacturing picture.
IEN: What innovations are in store for users of MH equipment?
Brittingham: Two important aspects for dock equipment users that will play into product development are cost control, as spearheaded by lower maintenance, and simplicity. Several recent product introductions from SPX Dock Products typify this direction for the company.
For years, warehousing operations have been asking for a better solution for their loading dock needs than edge-of-dock levelers, portable plates, and many types of mechanical pit-styled dock levelers can provide.
The LoadHog from SPX Dock Products is a modular dock bridge for spanning the gap between the warehouse and the trailer. It easily mounts to the warehouse floor using only four heavy-duty anchor bolts and requires no concrete work.
This product is easy to install, easy to operate, provides superior environmental control, superior sanitary and rodent control, improves loss prevention, and provides a lower total cost of ownership than conventional solutions.
Like installation, activating the LoadHog is also simple and easy. Once the trailer is positioned and the dock door is raised, the dockworker simply steps on the release pedal and gently pushes the deck forward. The LoadHog descends slowly into the trailer.
Once loading or unloading is complete, the dockworker pivots the operating handle and raises the deck to its stored and locked position. LoadHog only requires approximately 38 lb of lifting force to store.
The deck length, combined with the lip and bumpers, allows access to a large range of trailers, including refrigerated and container trucks. LoadHog''s unique arc design and raised side housings provide structural integrity that can withstand forklift traffic and heavy loads. The 17 in. pre-ramp allows smooth transition from the warehouse floor to the deck.
LoadHog stores vertically inside the warehouse and allows the dock door to close tight against the floor, minimizing energy loss and the threat of employee theft. No concrete pit means no sanitary issues related to debris or rodents. Also, LoadHog provides greater protection against accidental forklift runoff.
As for a new power approach to dock leveler operation, the SPX Air Bag™ Dock Leveler incorporates simple pushbutton controls and an air bag lifting system. This combination results in reduced operating costs and greater dock productivity and safety.
The Serco Air Bag Leveler features a high-volume, low-pressure airbag lifting system similar to ones used successfully in repair and rescue operations for more than 50 years. Activated by a simple 10 amp fan motor and an air bag lifting system that''s safe, strong, and reliable, the revolutionary Serco Air Bag™ Dock Leveler delivers powered-dock leveler performance at a cost comparable to that of mechanical dock levelers.
Serco''s Clean-Frame™ design keeps the pit area clear and obstruction-free. The simple operation and clean, efficient design provide a low lifetime cost of ownership and a level of performance unequaled in the industry.
The lifting bag is constructed of polyvinylchloride-coated polyester fibers, proven resistant to chemical exposure and rodent damage, and safe to operate under temperature extremes of -65°F to +150°F.
The Air Bag Dock Leveler is activated by a single pushbutton. When the pushbutton is pressed, the fan motor inflates the bag and the dock leveler rises. At the top of the lifting cycle, the leveler''s lip automatically extends and the leveler floats down into position on the back of the trailer.
After loading or unloading is complete, the dock attendant again pushes the button to activate the lifting system and the leveler rises. When the attendant releases the button, the lip lowers to a pendant position and the leveler returns to its stored position.
Product integration is also a prime consideration. Along with providing every product necessary for a safe, clean, and efficient dock, SPX Dock Products offers their Master Control Panel as a means of coordinating the functions of this equipment. Doors, dock levelers, and truck restraints can be interlocked for proper operation.
This device has a programmable logic PLC. The users can set up the sequence of operation for the dock to meet their needs, traffic flow, and the way they handle truck shipments. To ensure smooth operation of this equipment, the Master Control Panel has diagnostic indicator lights.
IEN: What steps are being taken toward safety?
Brittingham: One crucial aspect for dock safety is that the truck trailer needs to be securely held at the dock. Any gap between the truck and the dock threatens forklift driver safety with the vehicle coming to a dead stop when accessing the truck, or worse, driving off the dock.
From the standpoint of the operation, improper truck restraint can cause damage to the truck ICC bar, failure to release the truck, or maintenance headaches.
SPX Dock Products offers several solutions, using two different designs. The Pit Bull Safety-Loc Series locks on tight, engaging a trailer''s rear impact guard and securing it more effectively than rubber wheel chocks. Serco Pit Bull Safety-Loc restraints are most compatible with the new rear impact guards because of their non-impact, low-profile design.
Serco Pit Bull Safety-Loc series powered restraints provide automatic pushbutton activation with advanced electronics and communication systems for increased dock safety and security. Depending on the dock, the Pit Bull is available as a driveway or recessed wall-mounted units, offering either hydraulic or mechanical operation.
Serco Pit Bull Safety-Loc Series restraints feature dual locking positions at 7 in. and 11in. from the face of the dock bumpers. The unique dual locking design restricts trailer movement while also providing additional horizontal range for recessed, wider, and bent rear underride guards. Pit Bull restraints can effectively engage virtually any rear impact guard configuration.
The Kelley Hidden Hook is a recessed, pit-mounted design that provides a clean, unobstructed dock area when stored. The hydraulically activated Hidden Hook effectively controls trailer movement by grabbing and holding the rear impact guard throughout the loading and unloading process.
The retractable hook literally disappears into the dock wall and is protected from snow and ice buildup, which can impede the operation of externally mounted restraints. The restraint will not hinder the operation of snow removal equipment or ground-level forklift-to-dock operations.
Both restraints cleanly release the trailer with no hangup when the truck is ready to pull away from the dock.
IEN: How do you cope with the pressure of evolving standards?
Brittingham: It is our customers in the plants and DC''s who are continually on top of the changes within the industry. So that we know what they know, our regional managers stay in constant contact. Rather than simply having a relationship based on the next sale, our representatives see themselves as dock consultants and check in with their accounts regularly to determine developing needs. This input has led to a continual stream of new SPX Dock Product development.