Modern Materials Handling - November 2012

PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION, WAREHOUSING AND MANUFACTURINGmmh.comNovember 2012®Doug Jones, executive vicepresident of global supplychain operations, MSCMSC Industrial Supplydelivers onsame-dayshipping 18SHOW PREVIEWProMat 2013: What’s newand what’s next 26READER SURVEYPulse on pallets 34+ Special Webcast:November 15 at 2:00 p.m. ETGo to: mmh.com/2012palletsSPECIAL REPORTWarehouse/DC surveyresults: Mixed signals 48

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UP FRONT Breaking news you should knowFilmLOC and Knapp LogisticsAutomation join RPAFilm lOC and Knapp Logis ticsAutoma tion have joined the ReusablePackaging Association (RPA), broadeningthe types of reusable solu tions andservices represented. FilmlOC offers apatented, silicone-free plac ard holder forlabel ing and re-labeling reusable containers and totes, racks, and other items.Knapp provides reusable managementsolutions, including a comprehensivesys tem solu tion for sort ing all types ofcontainers automatically.“We became mem bers because ourval ues are con sis tent with those of theRPA’s,” said Shirl Handly, pres i dentof Film lOC. “We have been longtimesup port ers of envi ron men talcauses—sup port ing local farms andbusi nesses, and reusing and recy clingwhen ever pos si ble.”“Knapp offers automa tion andser vices for all aspects of reusablessort ing and man age ment that complement the prod ucts and ser vicesof other mem bers of the RPA, makingthe over all sup ply chain moreeffec tive and cost effi cient, all theway through to the end user,” saidRedPrairie and JDA Software to mergeRedPrairie and JDA Softwareannounced on November 1 that theyentered into a definitive merger agreement.The combined entity will offera broad portfolio of solutions and servicesto manage global supply chains.The transaction has a total enterprisevalue of approximately $1.9 billion.The board of directors of JDA hasapproved the transaction, whichwill create one of the largest globalsoftware companies with combinedrevenues of over $1 billion.Following completion of the transaction,Hamish Brewer, president andNelson Company launchespackaging design centerCEO of JDA, is expected to leadthe combined company as its CEO.RedPrairie’s CEO, Michael Mayoras,will remain on the board of the combinedcompany.“This is a strong combination of twoleading companies with highly complementaryproduct suites,” said Brewer.“It will give businesses the powerto better manage global commercethrough a new world of capabilities.The combined company will have aunique ability to address our customers’increasingly complex needs with afull spectrum of solutions.”Companies looking for sustainable packagingsolutions to cut packaging costs, reduce waste anddecrease product damage have a new resource inThe Nelson Technical Center. Recently launched byThe Nelson Company, an international pallet andtransport packaging solutions provider, the center offers expertise in the fieldof pallet design, testing and custom packaging.John Clarke will serve as director of the center. “Our customers are runningwith leaner packaging and sourcing personnel today,” Clarke said. “Weare being asked to take a more integrated role with our partners to assistwith many of these activities. The center expands our capabilities to assistcustomers—allowing them to focus on their core activities while we managepackaging projects for them.” Clarke has his master’s degree from VirginiaTech, and worked in the Virginia Tech Pallet Research Lab for 10 years underthe direction of Marshall White. His last six years at Virginia Tech, Clarke wasdirector of the Virginia Tech Center for Unit Load Design.Jerry John son, mar ket ing man ager atKnapp. “By bring ing our 10 years ofexpe ri ence in the Euro pean mar ketand work ing col lab o ra tively with othermem bers, we can build the mar ket forreusables in the U.S.”AIM announcesparticipation atProMat 2013The Association for AutomaticIdentification and Mobility (AIM)has announced its participation inProMat 2013, which will be heldJanuary 21-24, 2013, in Chicago.“This is anincredibleopportunityfor AIM and itsmembers topartner againwith MHIA andto expand AIM’svisibility,” saidChuck Evanhoe,chairman ofthe AIM boardof directors. “While it may seemthat bar codes, radio frequencyidentification (RFID), mobile commerceand mobile IT are becomingubiquitous, these technologiesare often used at a minimal levelbecause organizations don’t fullyunderstand all the benefits thesetechnologies can offer. A visit to theAIM pavilion offers a chance to seefirst-hand the innovative solutionsavailable today.”AIM companies participating inthe pavilion include: Evanhoe &Associates, Gulton, Metalcraft,Portsmith Technologies, TharoSystems and Videx.mmh.com Modern Materials Handling / N o v e m b e r 2 0 1 2 3

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VOL. 67, NO. 11®PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION,WAREHOUSING AND MANUFACTURINGDoug Jones, executive VP ofglobal supply chain operations,helped MSC Industrial embracegrowth and stay competitive.COVER STORYPhotography: Allen Wycheck/Getty ImagesSYSTEM REPORT18 MSC Industrial Supply deliverson same-day shippingThe distributor of industrial supplies delivers on customer serviceguarantee with automated approach.23 Pick and consolidateMSC’s new order fulfillment system rapidly picks and consolidatesmulti-line orders for quick cycle times.FEATURESSHOW PREVIEW PROMAT 201326 What’s new and what’s nextWith more than 800 exhibitors, three keynotes and an extensiveeducational program, ProMat 2013 looks to be the biggest editionof the show yet.READER SURVEY34 The pulse on palletsFrom wood to plastic to pallet pools, our readers tell us what’simportant in pallets.EQUIPMENT REPORT40 Supply chain software:Should I upgrade my WMS?The old rhythms of WMS upgrades are changing. It’s easierthan ever for customers to stay current and competitivewithout breaking the bank.PRODUCTIVITY SOLUTION46 Automation improves process flowAiming to reduce manual tasks, company reaps unexpectedproductivity improvements.47 AGVs keep product movingaround the clockPackaging manufacturer’s flexible new fleet helps repetitivetasks become efficient and safe.60 Secondswith IanHobkirkDEPARTMENTS & COLUMNS3/ Upfront7/ This month in Modern14/ Lift Truck Tips: Cold storage16/ Packaging Corner: Unit load design58/ Focus On: Automated storage62/ Product Showcase66/ 60 seconds with...NEWS10/ State of materials handling11/ Toyota Industries Corporationto acquire Cascade12/ Physical Internet could increase profits,reduce carbon emissions, study findsSUPPLEMENT: 2012 WAREHOUSE/DC OPERATIONS SURVEY46 Mixed signalsA record response to our annual survey reveals thatreadership is divided in terms of investment: One sideremains cautious, while the other is on the verge ofmaking significant changes to their warehouse/DCoperations.Modern Materials Handling ® (ISSN 0026-8038) is published monthly byPeerless Media, LLC, a Division of EH Publishing, Inc., 111 Speen St, Suite200, Framingham, MA 01701. Annual subscription rates for non-qualifiedsubscribers: USA $119, Canada $159, Other International $249. Singlecopies are available for $20.00. Send all subscription inquiries to ModernMaterials Handling, 111 Speen Street, Suite 200, Framingham, MA 01701USA. Periodicals postage paid at Framingham, MA and additional mailingoffices. POSTMASTER: Send address changes to: ModernMaterials Handling, PO Box 1496Framingham MA 01701-1496.Reproduction of this magazine inwhole or part without written permissionof the publisher is prohibited. Allrights reserved. ©2012 Peerless Media, LLC.mmh.com MODERN MATERIALS HANDLING / N O V E M B E R 2 0 1 2 5

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®This month in modernEDITORIAL OFFICES111 Speen Street, Suite 200Framingham, MA 01701-2000(800) 375-8015MICHAEL LEVANSGROUP EditorIALDIRECTORMichael LevansGroup Editorial Directormlevans@peerlessmedia.comBob TrebilcockExecutive Editorrobert.trebilcock@myfairpoint.netNoël P. P. BodenburgExecutive Managing Editornpbodenburg@peerlessmedia.comJosh BondAssociate Editorjbond@peerlessmedia.comSara Pearson SpecterEditor at at Largesara@saraspecter.comRoberto MichelEditor at at Largerobertomichel@new.rr.comJeff BermanGroup News Editorjberman@peerlessmedia.comMike RoachCreative Directormroach@peerlessmedia.comWendy DelCampoArt Directorwdelcampo@peerlessmedia.comDaniel GuideraIllustrationdaniel@danielguidera.comBrian CeraoloGroup Publisherbceraolo@peerlessmedia.comPeerless Media, LLCwww.peerlessmedia.comKenneth MoyesPresident and CEOEH Publishing, Inc.Brian CeraoloPublisher andExecutive Vice PresidentPeerless Media, LLCMAGAZINE SUBSCRIPTIONSStart, renew or or update your FREEmagazine subscription at atwww.mmh.com/subscribe.Contact customer service at: at:Web:www.mmh.com/subscribeEmail: mmhsubs@ehpub.comPhone: 1-800-598-6067Mail:Peerless MediaP.O. Box 1496Framingham, MA 01701eNEWSLETTER SUBSCRIPTIONSSign up up or or manage your FREEeNewsletter subscriptions at atwww.mmh.com/enewsletters.MSC honorssame-day pledgeThe term “same-day shipping” hasbecome inexorably linked to thecustomer-service pledge of any e-tailer looking to stay in the game. And whileAmazon and subsidiary Zappos built theirfortunes on it, rarely do we turn our attentionsto how same-day shipping can helpan industrial distributor build competitiveadvantage—and even take the lead in itsrespective market.You can add MSC Industrial Supply tothe list of companies that built its reputation—andsubsequent success—on thesame-day pledge. In fact, the distributor ofindustrial supplies to durable goods manufacturershas been putting its money whereits month is since 1991: “We’ll ship yourorder the same day you place it or send youa cash-back guarantee.”But what’s most impressive about MSC’ssuccess is how that simple pledge pushedthe distributor to stay on the cutting edgeof current best practices—from a pick-andpassorder fulfillment process in 1991 to anewly automated, RF-driven process thatkeeps up with the multi-pronged, e-fulfillmentchallenge of today.As executive editor Bob Trebilcock chroniclesthis month, when MSC first launched theprogram, different regions of the country haddifferent order cut-off times—some regionscould place orders up until 8 p.m. ET whileothers had until 1 p.m. ET.But in these early stages, MSC was ableto make good on its promise becauseorder times tended to be fairly consistent.“When most of our customers phoned orfaxed orders in, we would get 45% of ourvolume for the day before lunch,” DougMemberMember ofJones, executive vice president of globalsupply chain operations, tells Trebilcock.“The pick-and-pass method served us wellfor years.”But between 2005 and 2012 the company’sbusiness doubled, mostly throughacquisitions, and the supply chain team felta sudden jump in new volume that had tobe absorbed into the existing system. Andthis surge just so happened to take placeduring the same time period that customerorder patterns were changing due to theInternet.“Instead of getting 45% of our volumebefore lunch, we now get 60% to 70% ofour volume between 3 p.m. and 6 p.m.,”Jones says. “If you take an order at 4:45p.m. in a region with a 6 p.m. ship time, thatthree-hour cycle time is a problem.”What unfolds on page 18 is an e-fulfillmentevolution success story that’s basedon more brains than brawn. It incorporateswave-planning software, highspeedbelt conveyor, narrow-belt sortation,put-to-light technology and mobilecomputing and bar code scanning. Thenew system has resulted in reduced ordercycle times and one order cut-off-time forsame day shipping no matter where thatcustomer is in the country.“For many retailers and industrial distributorslike MSC, the ability to order atany time of day and from any device createdby the Internet has really changedthe game,” says Treblicock. “Now, distributionand order fulfillment systems needto keep pace with these new demands,and MSC is a great example of this phenomenon.”WinnerJesse H. NealCertificates of Meritfor JournalisticExcellenceOfficial Publication ofwww.peerlessmedia.commmh.com Modern Materials Handling / N o v e m b e r 2 0 1 2 7

WHERE SUPPLY CHAIN SOLUTIONS CONNECTProMat 2013 is the must-attend event in the manufacturing and supply chain industry. From January 21-24, 2013,leading innovators will showcase solutions that will open a world of possibilities to:• Streamline operations and improve visibility• Maximize efficiency and flexibility• Cut costs and increase profitability• Speed time to market• Reduce your carbon footprintSponsored by:Collocated with ProMat 2013Find us on:Scan this QRcode to register.

PROMAT 2013KEYNOTE SPEAKERSSteve ForbesChairman andEditor-in-Chief,Forbes MediaNavigating the New PoliticalClimate for Business Growthand SuccessWith the presidential inaugurationthe day before ProMat opens, SteveForbes assesses the impact of thePresident and his administration onthe future of the economy and businessgrowth. Mr. Forbes will provide insightsand strategic advice for businesssuccess during these difficult times.Henrik I.ChristensenKUKA Chair ofRobotics & Directorof Robotics,Georgia TechThe Impact of Roboticson Economic GrowthDuring the last few years, a newwave of robotics has emerged that isrevolutionizing manufacturing anddistribution operations. Dr. Christensenwill detail how these advances combinedwith core business drivers willhelp advance future economic growth.REGISTER TODAY FOR PROMAT 2013!Visit www.ProMatShow.com for free registration.Edie WeinerFuturistThe Future of Material Handling,Logistics and Supply ChainModerated by: Edie Weiner, FuturistPanelists:George Prest, CEO, MaterialHandling Industry of AmericaRick Blasgen, President and CEO,Council of Supply ChainManagement ProfessionalsMichael J. Mikitka, CEO, WarehousingEducation and Research CouncilLiz Richards, Executive Vice President,Material Handling EquipmentDistributors Association

FollowModern Onlinefacebook.com/mmhmagazineTwitter | @modernmhmagWeb | mmh.comECONOMYState of materialshandlingAT MHIA’S ANNUAL MEETING, SLOW BUT STEADYGROWTH REPORTED.BY BOB TREBILCOCK, EXECUTIVE EDITORLAST MONTH, at the annual meetingof the Material Handling Industry ofAmerica (MHIA) in San Antonio, theoverall news was good. Hal Vandiver,MHIA’s long-time economist andpresident of F. Hal Vandiver & Associates,and representatives for eachof the product groups, offered theireconomic outlooks.The outlook is slow and slowing,but with steady growth over the nextfew years. The two product categoriespredicting a modest decreasein their markets, AGVs and AS/RS, are coming off record yearsin 2011. In the case of those twoproduct groups, flat’s still prettygood. Looking at the industryas a whole, Vandiver expectsthe national GDP to grow in the2% to 3% range for the nexttwo to three years and industrygrowth of 6% to 8% for 2013.While many industries would bethrilled with 6% to 8% year-overyeargrowth, that’s roughly halfthe rate of growth from 2011. “Idon’t see things going south forus,” Vandiver said. “But I do seea declining rate of growth.”Vandiver’s cautionary note:“Watch Europe and China. Events inthe export market aren’t good for us.”Here is a rundown on how representativesof the product categoriesview their markets:Casters and wheels: Similar toVandiver’s outlook for the overallmarket, caster and industrial wheelmanufacturers expect a period ofdeclining growth—business will beup, but not as up as it has been.Industrial racks: The rack market isstill recovering from the Great Reces-sion, when sales dropped in 2009 by28%. The market is expected to be up1.2% in 2012 and up by 13% in 2013.Ergonomics and lift devices:Many labor trends are working in thefavor of the market for ergonomicequipment, including an aging workforce,more women in the workforceand the expanding Americanwaistline. Like the overall industry,ergonomic equipment manufacturersexpect growth at a declining rate.Overhead materials handling:Demand has been strong, especiallyfor overhead cranes. That demandis expected to continue at leastthrough 2013. The hoist market isexpected to be up by 11% in 2012;the crane market is expected to declineby 2% following a record year;and the overhead monorail market isexpected to be up by 14%. In 2013,expect a 5% increase in hoists; a1% decrease in cranes; and an 8%increase in overhead monorails.10 N O V E M B E R 2 0 1 2 / MODERN MATERIALS HANDLING mmh.com

Lift trucks: From 2009 through2011, the lift truck market grew by41%, making up some of the groundthe industry gave up in the recession.Because of that significant growth, theindustry expects to post 12% growth in2012 and 1% growth for 2013.Conveyors and sortation equipment:Coming off its second strongyear in a row, the market for conveyorsand sorters is looking at 17% to20% growth in shipments for 2012.The industry hasn’t posted a forecastfor 2013, but growth is expected tocontinue at a declining rate.AGVs and AS/RS: Both AGVs andAS/RS posted records sales in 2011,both in terms of actual dollars andnumber of units sold. In the AS/RSindustry, for instance, 2010-2011 willgo down as the longest and largestgrowth period in the industry’s history.For that reason, both productgroups expect negative growth in2012 followed by flat sales in 2013.Given the strong numbers thoseindustries posted in 2011, slightdeclines aren’t bad.Information technology: Themarkets for automatic data captureequipment and supply chain executionsoftware systems that managewarehouses, plants and transportationdepartments remain strong. Supplychain software is expected to growfrom 7.3% to 10.3% depending onthe application; and the overall ADCspace is forecast to grow by 7.5%.LIFT TRUCKSToyota Industries Corporation toacquire CascadeToyota Industries Corp.(TICO) and Cascade Corp.announced that they have enteredinto a definitive agreementunder which TICO willacquire 100% of the shares ofCascade for $65 per share incash in a transaction valuedat $759 million pursuant toa tender offer. The purchaseprice represents a 23% premiumover Cascade’s volumeweightedaverage share pricefor the 60 days ending Oct.19, 2012. The transaction hasbeen unanimously approved by bothcompanies.The transaction will create aglobal materials handling businesswith a wider spectrum of productsand a valuable platform for growth.Based in Japan, TICO is a leadingglobal materials handling, automotive,textile machinery and logisticscompany and a leading manufacturerof lift trucks. Based in Fairview, Ore.,Cascade is a leading internationalCascade is a leading manufacturer of lift truckattachments.manufacturer and distributor ofmaterials handling attachments andreplacement parts for the lift truckand construction industries. Underthe terms of the transaction, Cascadewill become a wholly owned subsidiaryof TICO.Robert C. Warren Jr., presidentand CEO of Cascade, said, “Ourcompany has concluded that the offerbeing made by Toyota IndustriesCorp., one of the world’s most admiredcompanies, represents an idealLogistics community assessesin wake of superstorm SandyMillions who bore the brunt ofsuperstorm Sandy are nowworking to assess the damage andbegin the hard work of rebuilding.As relief agencies work to identifyand assist those hardest hit, theAmerican Logistics Aid Network(ALAN) is connecting communitiesin need with concerned members ofthe supply chain community.“We are in communication withstate, regional, and national VoluntaryOrganizations Active in Disaster(VOADs) as well as emergencymanagement agencies,” said JockMenzies, president of ALAN, a nonprofitorganization that engages thesupply chain community in supportof humanitarian relief efforts. “Weare standing by to provide assistancefor transportation services,staging areas, storage, expert advice,and other vital resources.”To make in-kind donations ofneeded supply chain and logisticsgoods and services, visit alanaid.org/relief-needs.php.combination of attractive return toour shareholders, continuing serviceto our customers, and stability andopportunity for our employees.”“Cascade has a strong reputationfor providing customers with the latesttechnology in materials handlingattachments for lift trucks and iswidely considered to be the innovativeleader with high-quality, customizableproducts,” Tetsuro Toyoda,TICO president and representativedirector, said. “We’ve long knownCascade as a reliable and world-classsupplier to our materials handlingbusiness, and we look forward tobetter meeting our customers’ logisticalneeds by broadening our lifttruck business.”Warren will continue to lead thebusiness after the closing of thetransaction, and it will remain basedout of Fairview.mmh.com MODERN MATERIALS HANDLING / N O V E M B E R 2 0 1 2 11

MMH-Island-Ryson-BoothNov.indd 110/23/12 11:00 AMdioxide emissions associated withroad-based freight carriers increasedby nearly 15%, up to 517 trillion gramsper year.As a potential solution, the PhysicalInternet proposes an efficient systemin which global supply chain logisticsare enabled by an open, intermodalsystem that uses standard, modularand re-usable containers, real-timeidentification and coordinated routingthrough shared logistics facilities.Meller and his research colleaguesdeveloped models to quantify theeffects on profits and sustainability ifindustry stakeholders shifted to a fullyinterconnected logistics system. Theyfocused on principal potential participants—consumer-packaged-goodsmanufacturers, retailers, diversifiedmanufacturers/shippers and transportationservice providers. They usedtheir results to predict the impact ofthe Physical Internet on key performanceindicators and to motivate organizationsto consider moving towardadoption of the system.The models showed that the PhysicalInternet would increase stakeholderprofits by $100 billion annually andwould reduce annual carbon emissionsfrom road-based freight by morethan a half. These are conservativeestimates, based on only 25% of allfreight flows in the United States. Theresearchers also were surprised bytheir discovery that the shift towarda shared system would lead to moreinventory holding points located closerto customers than the current distributioncenters.One major consequence of thisshift, Meller said, would be morepredictable short-haul or relay shuttleruns, rather than the prevailing pointto-pointor hub-and-spoke designsused today. These shorter runs wouldhave many positive consequences—higher profits for stakeholders, savingsfor consumers, better customer serviceand lower driver turnover rates.“We predict that a relay networkwould get drivers home more often,which we believe would drasticallyreduce driver turnover,” said KimberlyEllis, engineering professor at VirginiaTech and co-author of the study.Finally, the research showed a net reductionin prices paid by the consumer.“The technology to make this happenis currently available,” Meller said. “AllSave Spaceand IncreaseThroughput.Like to minimize the cost of ownership? Ryson can help. Our SpiralConveyors need less floor space than conventional conveyors and arefaster and more reliable than any elevator or lift. All our products aredesigned for low maintenance and long life and our proprietary modularconstruction makes future reconfiguration cost effective.Quality and service come first at Ryson. We are the number one spiralmanufacturer in the USA. For application assistance or more information,give us a call or visit www.ryson.com.See our Spirals run at PROMAT 2013, Booth 2336300 Newsome Drive • Yorktown, VA 23692Phone: (757) 898-1530 • Fax: (757) 898-1580VERTICAL CONVEYING SOLUTIONSparties, including the consumer, willbenefit. Now we need industry partnersto pilot a mini-Physical Internet and allowus to share those results with othersin the industry.” The researchers’ resultsare part of a two-year project sponsoredby the National Science Foundationand 18 industry leaders. mmh.com MODERN MATERIALS HANDLING / N O V E M B E R 2 0 1 2 13

lift truck TIPSAs temperatures fall, so cancore competenciesFleet owners can minimize damage and boost productivity by ensuringboth operators and their equipment stay at optimal temperatures.By Josh Bond, Associate EditorIn every business, things change—and that includes thetemperature. When lift trucks are made to transition fromambient temperatures to sub-zero environments, condensationand the expansion or contraction of structural elementscan quickly cause serious damage. Selecting equipmentsuited to the working environment is a good firststep, but ideal conditions rarely remain that way. By carefullyconsidering a cold storage lift truck’s usage, batterycycle and needed modifications, fleet owners can preventneedless damage and ensure consistent productivity.“Any time you talk about lift trucks, whatever thetemperature and environment, the focus should be onthe application first,” says Bill Pfleger, president of YaleDistribution, who emphasizes a focus on the throughputrequirements. “Then you can talk about what equipmentis needed to optimize the application.”It is not enough to note the reduction in batteryperformance associated with operation in cold environments.According to Pfleger, a customer must understandbattery power, how it will be refreshed, and how the truckperforms throughout the battery cycle. Issues aroundergonomics and operator comfort are more pronouncedin cold storage, but some users evaluate equipment in avacuum.“An operator might be comfortable enough in the lifttruck’s cabin while wearing plainclothes, but it’s a differentstory when they don a freezer suit,” says Pfleger. “Don’tjust demo a lift truck on the dealer’s showroom floor. Considerhow it will work in the real world.”When evaluating new equipment for cold storage, customersare often overly price sensitive and do not considerthe need for additional heating elements to ensure operatorcomfort and proper function of controllers. “A customermight want to shortcut certain recommendations. Youmight save hundreds now on heaters, but you’ll pay laterwhen operator productivity goes down,” says Pfleger.And, you must be aware of going back and forth betweenambient and freezer environments, he says. Someapplications use fans to blow condensation off the truckto ease the transition. The optimal setup is a lift truckleaving the freezer temperature of, say, 20 below, and“warming up” in a cold room that’s just below freezing.The battery room might be located in the cold room. If itbecomes necessary to use a dedicated freezer truck in anambient environment, the cold room is a good intermediaryto prevent frost from immediately building.Customers should be prepared for different maintenanceprograms for lift trucks that spend full time or part time inthe freezer. Maintenance cycles tend to be shorter for theselift trucks as fluids, oils and greases break down differently.“Make sure the equipment is appropriate to the applicationand that the provider has a good understandingof how you intend to use the equipment,” says Pfleger.“People will call and say, ‘I need a sub-zero truck. Send aquote.’ In that scenario, you’ve got a chance of getting itright, but you’ve got a better chance of getting it wrong,so it’s critical to understand all facets of the applicationand use.”Josh Bond is Modern’s associate editor and can be reachedat jbond@peerlessmedia.com14 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

YOUR OPERATION NEEDS TO BE MORE EFFICIENT THAN EVER.YOU NEED TO CUT COSTS AND INCREASE PRODUCTIVITY.AND THERE’S NO ROOM FOR ERROR.Hyster ® lift trucks are designed tohelp you get more done with less.In fact, the Hyster CT uses up to 12%less fuel than the leading competitors,but don’t just take our word for it.In an independent survey, currentcustomers ranked Hyster #1 in TotalCost of Ownership. *To see how our tough, reliablelift trucks finished first, visithyster.com/TCO.*Peerless Media Research Group, 201112HST5683© 2012 Hyster Company. Hyster and are registered trademarks of Hyster Company.hyster.com

packaging cornerIs your unit load sustainable?Better test it firstTo determine how changes in packaging will impact unit loadstability, many companies are turning to a transport test lab.By Sara Pearson Specter, Editor at LargeTo achieve sustainability goals,companies have been makingchanges to the individual componentsof a unit load—re-engineeringcardboard boxes, pallets and stretchwrap, for example, to reduce materialcost and waste. The downside, assertsRalph Rupert, manager of unit load technologyat Millwood, can potentially be areduction in unit load stability.“Individually, those packaging changesmay not have any impact on the integrityof the unit load during storage andtransport,” Rupert says. “But when all thecomponents interact, that’s when stabilitycan be compromised and product damagecan occur.”Take stretch wrap film, for example.Although wrapping a load with a thinnerfilm may require less material, its overallcontainment force level may not besufficient to secure a load placed on athinner pallet.“If the pallet is not stiff enough, it will actually directmore vibration forces from over-the-road travel into theload, which can overpower the film and potentially causethat load to fail,” explains Rupert. “The interaction ofboth components needs to be looked at together to betterunderstand the performance issues, so sustainabilitycan be maintained or improved.”To determine how changes in packaging will impactunit load stability, it’s important to use a transport test lab.In Rupert’s lab at Millwood, he tests and analyzes howvibration, impact and compression forces affect a unitload to ensure that shippers are getting the level of performanceand sustainability that they need. Testing canbe undertaken for a variety of reasons, including verifyingthe use of a new packaging product, seeking processimprovements or for damage remediation.Because it employs rapid cycle methodologies, thetesting is usually accomplished in half a day and includesfindings, an explanation of the observations and recommendationsfor improving load stability. And it’s affordable,too, typically costing less than a unit load of damagedproduct, he says.Besides, adds Rupert, “for every gain in package sustainability,there is a greater potential to lose those gainsthrough damaged goods. Because as soon as any goodis damaged, there’s waste associated with that damageas well as the cost, raw materials and energy required toremanufacture a replacement item—not to mention a lossin customer satisfaction.”Sara Pearson Specter is an editor at large with Modern andcan be reached at sara@saraspecter.com.16 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

MSC Industrialdelivers onThe distributor of industrialsupplies delivers on customerservice guarantee withautomated approach.By Bob Trebilcock, Executive EditorDoug Jones,executive vicepresident ofglobal supplychain operationsWave planners (inset) builda wave of orders based onactivity in the building andwhen orders will ship (right).Allen Wycheck/Getty Images18 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

MODERN system reportSupplysame-day shippingIn the age of the Internet, whereprice comparisons are a mouse clickaway, customer service offeringshave become a competitive weaponfor many direct-to-consumer businesses.Just look at how Amazonchanged the game by offering freeshipping.While it may not receive as muchattention, the ability to deliver oncustomer service is a competitiveweapon in the business-to-businessspace as well. In fact, same-dayshipping has been a cornerstone ofMSC Industrial Supply Company’sapproach to beating the competitionfor years.Based in Melville, N.Y., the distributorof industrial supplies todurable goods manufacturers builtits market-leading position witha simple promise, explains DougJones, executive vice president ofglobal supply chain operations:“We’ll ship your order the same dayyou place it or send you a cash-backguarantee.”Jones, who has to sign those cashbackchecks, says the service guaran-tee is a reflection of the company’scommitment to meeting the needsof its customers. A few years ago,however, the combination of rapidgrowth and changes in the way customersplace their orders threatenedMSC’s model.“Nothing was broken,” Jones says.“But as we looked ahead, we couldsee that we needed to revamp ourprocesses to ensure that MSC’s distributioncapabilities would remaina competitive weapon for years tocome.”Working with a systems integrator(Fortna, fortna.com), MSC transitionedfrom a paper-based, pickand-passorder fulfillment processto an RF-driven process that picksall of the lines for an order simul-taneously and then consolidatesthem before sending them throughan automated packing station.The new solution included:• A wave-planning software applicationdeveloped by MSC to prioritizeorders according to variablessuch as ship time;• High-speed belt conveyor andnarrow-belt sortation to routecartons through the facility;mmh.com MODERN MATERIALS HANDLING / N O V E M B E R 2 0 1 2 19

modern system report• Put-to-light technology to consolidateand pack large or over-sizedorders; and• Mobile computing and bar codescanning.MSC rolled out the solutionin phases, starting with its640,000-square-foot distribution centerin Jonestown, Pa. Once a processproved itself in Jonestown, similarchanges were made in facilities inGeorgia, Indiana and Nevada.As a result, MSC was able to maketwo important changes to its operations.First, the new system reduced theorder cycle time, what MSC refers to asits print-to-ship time, from more than3 hours to about 45 minutes. Print-toshipmeasures the time from when anorder is released from the warehousemanagement system (WMS) until it’sready to go out the door.Second, that reduced cycle timeallowed MSC to offer one order cut-offtime for same-day shipping to its customers,no matter where they are locatedin the country. It also now offers nextdaydelivery for orders placed before 8p.m. ET—at no additional cost.“We were able to lower our cost toserve and exceed our customer serviceobjectives,” says Jones.Growth and diminishing returnsToday with $2.3 billion in annual sales,the company serves more than 300,000industrial customers from distributionSmall parts are stored in a reserve storage area.In the slow-moving SKU area, merchandise selectors pick to pallets fromman-up lift trucks.centers in Jonestown, Atlanta, Elkhartand Reno. Each distribution center isin the 600,000- to 700,000-square-footsize with the ability to scale to morethan 1 million square feet.Customer service has been thecornerstone of MSC’s value propositionsince the company was foundedin 1941. It published its first catalogand opened its first distribution centerin 1964. There have been many firstssince then: MSC was one of the firstdistributors to develop a computerizedinventory management and order processingsystem; one of the first to establisha fully integrated quality assurancedepartment; and one of the first to offerone- and two-day UPS delivery.MSC launched its hallmark samedayshipping guarantee in 1991. Whenthe program was first launched, Jonesexplains, different regions of the countryhad different order cutofftimes. Some regions, forinstance, could place ordersup until 8 p.m. ET whileothers had 1 p.m. ET cutofftimes. While the varyingcut-off times could be confusing,especially to nationalcustomers with operations indifferent parts of the country,MSC was able to makegood on its promise beforethe explosion of e-commercebecause orders tended tocome in steadily throughoutthe day.“When most of our cus-20 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

tomers phoned or faxed orders in, we would get 45% of ourvolume for the day before lunch,” Jones says.MSC’s old pick-and-pass order fulfillment system workedfine in that environment. After a call center representativetook an order, it would drop to the WMS. Once a paper pickticket was printed, the fulfillment process would begin whena merchandise selector, as order selectors are called, wouldget a tote in a 25-foot-high, narrow-aisle bin storage areareserved for slow moving items. Working on a man-up lifttruck, the selector would pick any items stored in this area.Since the average order is three to five line items, the totewas then passed to an induction area for a tri-level pickingmezzanine.The inductors would then route the tote to the firstpicking zone in the mezzanine where an item was stored.Following a pick, the tote was passed serially to subsequentzones until all the items were picked. After the last pick, thetote was conveyed to the packing area. In all, the processtook about three hours.“The pick-and-pass method served us well for years,”Jones says. However, as more people began to order electronically,several factors put a strain on operations.First, MSC’s business was growing rapidly. Between 2005and 2012, for instance, the business more than doubled,going from $1 billion a year to $2.3 billion a year. Some ofthat growth was organic, but some was also the result ofacquisitions, which led to what Jones describes as “lumpygrowth.” An acquisition resulted in a sudden jump in businessthat had to be absorbed into the system.More importantly, customer order patterns evolved withthe Internet. “Instead of getting 45% of our volume beforelunch, we now get 60% to 70% of our volume between3 p.m. and 6 p.m.,” Jones says. “If you take an order at 4:45p.m. in a region with a 6 p.m. ship time, that three-hourcycle time is a problem.”To cope, Jones says, MSC operated with more brawn thanbrain, adding people to pick zones to keep up with demand.That approach got the orders out the door, but at a cost to productivity.In 2005, Jones realized his processes needed to change.That year, MSC launched a process improvement programwith three goals:• Increase operational capacity: MSC needed to increaseits throughput capacity during peak hours so it could stopthrowing more labor at the problem.• Reduce cycle times: To meet the company’s ship guarantee,it had to reduce cycle times. In turn, that wouldimprove productivity and protect MSC’s service model.• Maintain quality: Since MSC primarily serves manufacturerswho rely on the distributor to keep their lines running,orders not only have to be timely, they have to be accurate.Jones insisted that changes be made with no negative impacton quality or customers.“We have no tolerance for errors,” Jones says.RIDG-U-RAKDelivered!“...we wereunder pressureto have all of our32,000 pallet positions ofrack operational. RIDG-U-RAKreally delivered... on-time and on-budget,and the way the rack system fittogether was very impressive...”Visit ridgurak.com orCall Toll Free: 1-866-479-7225See us at ProMat Booth 612Kirk HillGeneral Manager,Roberts TruckingProject: Roberts Trucking• 1.8 million Pounds of Pallet Rack• 32,000 Pallet Positions• Double Deep Selective• Slotted System• On-Time/On-Budget• Superior Quality... Fit and FinishRead more at ridgurak.com/RobertsThe most TRUSTED name in Rack!Selective Pallet Rack • Drive-In • Push-BackFlow • Pick Modules • Cantilever • Stacker CranesRoll-Out Shelving • Seismic Base Isolationmmh.com

modern system reportBreaking wavesFrom the outset, MSC rejected a BigBang in favor of a phased-in approach toimprovements. Changes were made infour phases over the next few years, startingwith Jonestown. The team likened itto waves hitting the beach, one at a time.The first phase was to replace thepaper-based picking system with anRF-driven system. In addition, MSCdeveloped a wave management softwareapplication in-house that allowedmanagers to select and prioritize theorders that were going to be filled. “Inour old system, a pick ticket was printedas soon as a new order was received inthe warehouse, regardless of when itshipped,” Jones says.With the wave management system,orders dropped into an electronicqueue. A wave planner acts as the quarterbackfor the system, building a waveof orders based on criteria such as whenthe orders will ship, which pick zonesare over-worked and which are underworkeddepending on the time of day.Instead of printing pick tickets, thoseorders are now distributed electronicallyto handheld mobile computers,creating a paperless, eco-friendly environment.Picks are verified by scanningbar code labels.In phase two, MSC brought in a systemsintegrator to replace the pick-andpasspicking method with a discreteorder picking system. The idea was tonot only further reduce cycle times, butstreamline the use of labor.“We used to have 15 people workingin the order induction center just todetermine how to route totes throughthe mezzanine,” says Jones. “That waslabor with no value-add.”The system integrator implementeda discrete picking and consolidationsystem. Instead of picking and passingtotes from one pick zone to the nextto fill a multi-line order in a series ofsequential picks, each line of an orderis now picked independently and simultaneouslyto a tote in whatever zonethe item has been stored. Once a merchandiseselector picks an item, affixesAfter picking, orders are consolidated andassembled and then sent to a packing areawhere they are prepared for shipment.a pick label and scans the item into atote, it is routed by a warehouse controlsystem to a centralized order consolidationarea with 256 accumulation lanes.Once all of the lines for an order havecollected in one of the lanes, a light signalsan associate to aggregate the itemsinto one tote and convey it to a packingstation.With the new picking process, MSCwas able to replace an inefficient rollerconveyor system and push diverts witha high-speed belt conveyor. A saw toothmerge combines the incoming conveyorlines into one line that feeds the totesto the order consolidation area. Narrowbelt sorters divert shipping containersto the right shipping lane.In phase three, MSC launched alean warehousing initiative to optimizeits labor force around the new materialshandling system.To round out the project, MSCimplemented an automated packingprocess earlier this year. Today, whena tote arrives at the packingstation, an associate verifiesthe contents of the order andplaces them in an open topshipping carton. From there,the automated packing systemdrops in a packing slip and anyother collateral material, addstransport packaging, right-sizesthe shipping container andautomatically seals a lid on thecarton. From there, it is conveyedto a top applicator for theshipping label and then on tothe shipping area.“We started in Jonestown,and then took the new processesto Atlanta, Elkhart andReno,” Jones says. “We’ve beengoing building by building.”The process improvementshave been substantial. In additionto reducing cycle timesby 75%, MSC has seen a significantimprovement in productivity.The 15 inductors, forinstance, are now involved inother jobs besides routing totes.“We have the same number of distributioncenter associates today to handlemore than $2 billion in business aswe had in 2005 to handle $1 billion,”says Jones.Just as important, the new capabilitieshave enabled MSC to improve onits customer service promise and drivesustainability benefits.“As a result of the success of thesystem, we moved our customer cutofftime to 8 p.m. ET throughout theUnited States,” says Jones. “We couldnever have done that with a threehourcycle time.” Jones adds the otherbenefit is that it enabled MSC tohave a more environmentally responsiblesolution to packaging—fromprinting less paper to moving fromstyrofoam to air pillows, leveragingreusable pallets and more. “For morethan 70 years MSC has prided itselfon exceeding our customer expectationsand being a responsible corporatecitizen,” he says.22 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

Pick and consolidateMSC’s new order fulfillment system rapidly picks and consolidatesmulti-line orders for quick cycle times.As part of its redesign, MSCIndustrial Supply transitionedfrom a traditional pick-and-passapproach order fulfillment system to amore streamlined solution. Now, thedifferent pieces of a multi-line order arepicked simultaneously and conveyedto a consolidation area where they aremarried together. The result is a highlyefficient process that has dramaticallyreduced cycle times.Receiving: MSC receives (1) severaldifferent types of shipments,including small parcel, less-than-truckloadand truckload shipments, andMSC Industrial Supply Co.,Jonestown, Pa.Size: 640,000 square feetProducts: Industrial suppliesThroughput: 40,000 lines per yearAssociates: 350Shifts per day/days per week: 3 shiftsper day, 5 days per weekocean containers. Floor loaded cartonsare palletized and then moved with lifttrucks to a receiving processing area (2).There, the contents are verified againsta purchase order. Small parcel shipmentsare processed in a separate area(3). Once the material has been verifiedand entered into the warehouse managementsystem (WMS), it is ready tobe put away into storage.Storage: Newly arrived productis putaway into storage in the reservestorage area (4), the slow moving itemsarea (5) and the tri-level mezzanine (6).Product destined for the mezzanineand slow moving area is put away afterhours so as not to interfere with orderShipping11Shipping sorter109 OrderPackingconsolidation78 Merge6Tri-level mezzanine4Reservestorage3Small parcelprocessing5Slow movingitems4 Reserve storage2 Receiving processing1Receivingmmh.com Modern Materials Handling / N o v e m b e r 2 0 1 2 23

modern system reportfulfillment processes. Cartons travel byconveyor from the receiving area to asortation area. There, associates buildpallets and carts with product that willbe stored in those areas. In the slowmoving SKU area (5), product is storedby associates on man-up lift trucks.The associate scans the bar code labelon a carton and on a storage location toconfirm the putaway in the WMS.In the mezzanine area (6), cartonsare placed on carts that are transportedto the right level for storage. Associatesfollow the same process to confirm theputaway in reserve storage (4).Picking: The picking process isinitiated when orders drop from theorder management system into an orderqueue in the WMS. At that point, anassociate referred to as a wave masterprioritizes the orders based on a varietyof criteria. That may include what timeof day the order has to ship, whether it’sa hot order or whether the wave masterwants to balance the work load in certainareas of the distribution center.Orders are entered into a waveplanning software application. Once awave has been built, picking tasks aredistributed electronically to the orderselectors’ RF guns, known as merchandiseselectors. The system is designedto pick all line items in an order individuallyand simultaneously and thento marry those items up in a centralizedconsolidation area.• Slow moving SKUs: Inthe slow moving SKU area (5),merchandise selectors work fromman-up lift trucks. Once a merchandiseselector arrives at a pickinglocation, he scans a locationbar code label and then scans alabel on the item. That will generatea shipping label that is appliedto the item or to a package if theitem is placed in separate packagingfor shipping. The item is thenscanned into a tote. Once thepicks in that area are complete,the tote is placed on a takeawayconveyor and the warehouse controlsystem routes it to the next stop. Singleline orders are conveyed directly to thepacking area (7). If the tote is part ofa multi-line order, it is conveyed to theconsolidation area (9).• Tri-level mezzanine: Merchandiseselectors perform similar steps in the trilevelmezzanine (6): after scanning locationand item bar code labels, the systemgenerates a new pick label for shipping.The item is then scanned into a tote thatis placed on a takeaway conveyor andmerge (8) in the mezzanine. The tote isthen conveyed to the packing area (7) orto the order consolidation area (9).Order consolidation: Totes withsingle line orders are conveyed directlyto the packing area (7). Multi-lineorders, however, must be consolidatedbefore they are sent to packing. Totesarriving from the various picking areasare merged onto one conveyor line at asaw-tooth merge (8). From there, totesare sorted into a two-level consolidationdeck (9). Each level has 128 accumulationlanes; each lane can hold upto seven totes, representing seven linesarriving from seven different areas of thebuilding. A light at the end of the mergealerts an associate when all of the itemsfor a single order have arrived and areready for the next step in the process.Since several orders may be readyat the same time, a blinking light alertsthe associate to the order that must beSystem suppliersSystem integrator, warehouse control system, waveplanning and put-to-light system: Fortna, fortna.comWarehouse management systems: MSC Industrial Supplymscdirect.com, developed internallyBelt and roller conveyor: Hytrol, hytrol.comNarrow belt sorters: TGW Systems, tgw-group.com/usLift Trucks: Raymond, raymondcorp.com, Crown, crown.comMobile computing and bar code scanning: MotorolaSolutions, motorolasolutions.comAutomated packing system: Savoye, savoye.comcompleted first. The associate marriesthe items for an order into just one tote.Once all of the items for that order arein a tote, it is conveyed to the packingstation (7).Packing: Both single-line andmulti-line order totes ultimately arriveat the packing station (7). There, apacker verifies that all of the itemsrequired for the order are present. Thepacker then places the items in an opentop shipping carton for that order. Next,an automated packaging system addsthe packing slip and printed marketingmaterials, adds protective transportpackaging such as air pillows, seals thelid on the carton, and diverts it to theright shipping lane (10), depending onthe carrier.Put-to-light order consolidationand packing: Some orders mayrequire more than seven line itemsor may call for large items that won’tfit into one tote. Those totes are conveyedto a put-to-light carton flow rackwith workstations on either side of therack. The put-to-light area is locatedunder the packing area (7). When atote arrives on one side of the rack, anassociate scans a bar code label on thetote. Lights on the carton flow rack tellthe associate where to place the tote.Once all of the totes for an order arein the carton flow rack, a light on theother side alerts a packer that the orderis ready to be finished. The packerplaces the items in an opentop shipping carton andit is conveyed to the automatedpackaging area (7)where it goes through thesame process mentionedabove in packaging.Shipping: Cartons thatcan be live loaded are conveyed(10) directly into atrailer. Other cartons areconveyed to a palletizingstation where pallets arebuilt for shipping and thenloaded onto a trailer. M24 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

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SHOW HOURSMonday, January 21, 201310:00 a.m. – 5:00 p.m.Tuesday, January 22, 201310:00 a.m. – 5:00 p.m.Wednesday, January 23, 201310:00 a.m. – 5:00 p.m.Thursday, January 24, 201310:00 a.m. – 3:00 p.m.What’s new and what’s nextWith more than 800 exhibitors, three keynotes and an extensiveeducational program, ProMat 2013 looks to be the biggestedition of the show yet.By Noël P. Bodenburg, Executive Managing EditorWith about two months to go before ProMat 2013opens, preparations for North America’s largestmaterials handling show are heating up.Nearly 30,000 visitors are expected to attendProMat 2013, which will be held January 21to January 24 in Chicago’s McCormick Place.Sponsored by the Material Handling Industry ofAmerica (MHIA), more than 800 companies willshowcase what’s new and what’s next in materialshandling and logistics equipment and systemssolutions. The show will also include three keynotesas well as an extensive educational program.“Companies are spending money on materialhandling solutions that improve productivity,”said George Prest, CEO of MHIA. “In 2011,attendees came to the show to solidify their purchasingplans. This year, attendees will be comingwith projects in hand and wallets open; they’relooking for the latest in innovations that can helpthem attain their goals.”Exhibits from industry, commerce and governmentwill be showcased throughout the300,000-square-foot show floor.“The 2009 installment of ProMat was the largestshow we’ve ever hosted, and we’re projectingthat 2013 will top that show both in terms ofexhibit square footage and attendance,” said Prest.In addition to ProMat, registered attendees26 N O V E M B E R 2 0 1 2 / MODERN MATERIALS HANDLING mmh.com

will also get free entry into Automate2013, held in McCormick Place North.Like ProMat, Automate (formerly theInternational Robots, Vision & MotionControl Show) is held just once everytwo years. The event is sponsored by theAssociation for Advancing Automation(A3) and its trade associations,which include the Robotic IndustriesAssociation (RIA); AIA, the global associationfor vision and imaging; and theMotion Control Association (MCA).Automate will showcase the full spectrumof automation technologies andsolutions.“It’s a natural fit for the associations,”Prest said. “In our industry, automationrepresents a large area of growth, andit’s at the top of everybody’s agenda rightnow as companies continue to seek toimprove efficiencies.”To make it easier for attendees tofind the solutions they are looking for,the ProMat 2013 show floor is dividedinto four solution-specific sections:• Manufacturing & AssemblySolutions Center: Featuring automatedassembly support, intelligentdevices, robotics, ergonomic and safetyequipment, work stations, light-rail andother assembly assist equipment andsystems for the manufacturing environment.• Fulfillment & DeliverySolutions Center: Showcasingsolutions for traditional or e-commerceorder fulfillment, order pickingand packaging, third-party logistics,warehousing, distribution or transportation.• Information Technology (IT)Solutions Center: Highlightingsupply chain software solutions,RFID, auto ID and data collection,transportation management systems,manufacturing execution systems,logistics execution systems, enterpriseresource planning and ordermanagement systems.• The Knowledge Center(Including the educational conference):Offering resources to educateand build awareness of what the materialhandling and logistics industry hasto offer the supply chain as a whole.KeynotesProMat will feature three keynote presentations,each offering insights fromexperts into future developments inrobotics, business and the supply chain.On Monday, Henrik I. Christensen,KUKA chair of robotics and director ofrobotics at Georgia Tech, will deliver thefirst keynote. In a presentation entitled“The Impact of Robotics on EconomicGrowth,” Christensen will detail howadvances in robotics are revolutionizingCelebrating innovationProMat 2013 will host the first-ever ProMat InnovationAward competition. The ProMat Innovation Award serves toeducate and provide valuable insights on the latest manufacturingand supply chain innovative products and services toProMat attendees. This award will begiven to winners in two categories:Best New Innovation and Best Innovationof an Existing Product. OnlyProMat 2013 exhibiting companiesare eligible for the award.The contest defines innovationas a new product, product line,technology or service or new applicationof existing products or technology that createquantifiable and sustainable results in terms of ROI, costsavings and customer satisfaction.Finalists must also participate in an on-site demonstration.Between 8 a.m. and 9:30 a.m. on Monday, Jan. 21, 2013,selected finalists will present and demonstrate their innovationin their booth on the ProMat show floor. A panel of judges willevaluate the selected product or service and choose the winnersin each category.Submissions are now being accepted. Finalists will be judgedby a committee of judges on the morning of Jan. 21, 2013, andthe award winners will be announced during a press conferencein The Hub on the show floor on Monday, Jan. 21, 2013.mmh.com Modern Materials Handling / N o v e m b e r 2 0 1 2 27

show previewmanufacturing and distribution operations,as well as share insights into howthese developments will propel futureeconomic growth.“We’ve seen tremendous progressin robotics and automation in materialshandling over the last few years,”explained Christensen. “There hasbeen a lot of development in automationthat does the handling tasksthat don’t require a lot of intelligenceand are physically challenging.Additionally, the use of robotic technologydecreases the amount of spacethat you need—and real estate is gettingincreasingly expensive.”On Tuesday, Steve Forbes, chairmanand editor-in-chief of ForbesMedia, will deliver the second keynotepresentation. Forbes will make recommendationsfor “Navigating the NewPolitical Climate for Business Growthand Success.”With the presidential inaugurationhaving just taken place, one-time presidentialcandidate Forbes will assess theimpact of the elected president andhis administration on the future of theeconomy and business growth. Havingserved two administrations, Forbes’keen ability to provide economic andpolitical insights on the most debatedissues of the day is trusted by businessleaders here and abroad.On Wednesday, the final keynotepresentation will feature a discussionof “The Future of Material Handling,Logistics and Supply Chain.” Settingthe stage for the discussion will beremarks from futurist Edie Weiner,president of consulting group Weiner,Edrich, Brown.“I will set the backdrop for whichthe future of materials handling, logisticsand supply chain will unfold,”explained Weiner. “I’ll talk about whyour thinking is stuck in yesterday, andstory continues on page 3228 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

100 picksevery 6 minutes!Efficient Goods-to-Person Order Fulfillmentthat Increases Your Return on InvestmentVisit Schaefer Systems' patented Goods-to-Person workstation in BOOTH #2003 at ProMat® tofind out how you can get 70% higher picking efficiency over traditional picking methods. Learnhow we achieve over 1,000 picks per hour and you can, too.The Goods-to-Person workstation has been designed with your employees' safety as a top priority.When you operate our station at the show, you will be able to actually see the ergonomics@work®.In return, your employees will have less down time due to work related injuries and a significantincrease in productivity, ultimately increasing your bottom line.Call us now and learn how we can help your business.(877) 724-2327news.ssi-schaefer.usSchaefer Systems International, Inc.BOOTH #2003AN MHIA INTERNATIONAL EXPOMcCORMICK PLACE CHICAGO JAN 21-24Also visit our Packaging Division in BOOTH #2023

show previewKnowledge Center to host 90+ free educational sessionsThink you know everything there isto know about how materials handlingmakes the supply chain work? Not so,according to the folks conducting the 90-plus free educational sessions located inthe ProMat 2013 Knowledge Center. Thesessions run in eight separate theatersfrom 10:30 a.m. to 4:30 p.m. on Mondayand Tuesday, and on Wednesday from10:30 a.m. to 3:00 p.m.“The On-Floor Seminars are presentedby industry experts in material handlingand logistics solutions,” said Amy Cunningham,manager of ProMat’s educationalseminars. “It’s a superb opportunityfor attendees to be educated on thelatest material handing technologies fromexhibitors, industry groups and researchinstitutions.”Topics range from best practicesreviews to maintenance to metrics. Detailedabstracts of each session, with keytakeaways for attendees, are included inboth the show program and in a specialseminar directory booklet. Only a few ofthe sessions run twice. Each theater holds100 participants, and it’s first-come/firstservedwith no standing room allowed,added Cunningham.Additionally, several industry groupswill be presenting the latest insightsinto their technologies. These sessionstypically feature three panelists fromdifferent companies discussing newdevelopments, applications and usesfor the equipment represented by theirgroup. “These industry group sessionsalways generate lot of interest and highattendance levels,” Cunningham said.Industry group sessions are as follows:Monday January 21• “KPIs for Maximizing Goods-to-Person Investment,” presented by theIntegrated Systems and Controls Council,12:45 to 1:30 p.m., Theater D.• “Can You Turn Your Green Conveyorand Sortation Initiatives Into Greenbacks?,”presented by Conveyor andSortation Systems, 1:30 to 2:15 p.m.,Theater I.• “The 21st Century Warehouse:Automation Prepared For The Future,”presented by the Automation Alliance,2:15 to 3:00 p.m., Theater F.• “Rack Storage - Fitness ThroughThe Life-Cycle,” presented by the RackManufacturers Institute, 3:00 to 3:45p.m., Theater C.• “Industrial Work Platforms, EquipmentPlatforms and Mezzanines,”presented by the Storage EquipmentManufacturers Association, 3:45 to 4:30p.m., Theater H.Tuesday January 22• “Multi-Channel Retailing: UpgradingYour Order Fulfillment Systems,”presented by Order Fulfillment Solutions,10:30 to 11:15 a.m., Theater I.• “Are Automatic Guided VehiclesRight For You? Customer Case Studies ofSuccessful AGV Applications,” presentedby Automatic Guided Vehicle Systems,11:15 a.m. to 12:00 p.m., Theater F.• “Optimized Wave Picking and Sortation:Beyond Connecting The Dots,”presented by the Integrated Systems& Controls Council, 12:45 to 1:30 p.m.,Theater B.• “Bridging Technologies UsingSingulation and Sortation,” presented byConveyor and Sortation Systems, 2:15 to3:00 p.m., Theater F.• “AS/RS Revolution – Six Steps ToSelecting The Right AS/RS For Your Business,”presented by Automated Storageand Retrieval Systems, 3:45 to 4:30 p.m.,Theater H.Wednesday January 23• “Multi-Channel Retail Order FulfillmentSolutions,” presented by OrderFulfillment Solutions, 10:30 to 11:15 a.m.,Theater E.• “Top 10 Reasons To Automate,” presentedby the Automation Alliance, 11:15a.m. to 12:00 p.m., Theater B.• “Using Metrics and SCE SystemsTo Drive Performance Improvement,”presented by Supply Chain ExecutionSystems & Technologies Group, 12:00 to12:45 p.m., Theater E.• “Industrial Shelving, Shop Furniture,Drawer Storage and Cabinetry,” presentedby the Storage Equipment ManufacturersAssociation, 12:00 to 12:45 p.m.,Theater I.• “Casters: Do They Matter? MakingThe Right Decision,” presented by Instituteof Caster and Wheel Manufacturers,12:45 to 1:30 p.m., Theater D.• “6 Reasons For Small And MediumCompanies To Implement Order PickingCarousels and VLMs,” presented by AutomatedStorage and Retrieval Systems,12:45 to 1:30 p.m., Theater H.• “How To Calculate Carbon Footprints:A Wood Pallet Example,”presented by College Industry Councilon Material Handling Education, 1:30 to2:15 p.m., Theater G.• “Warehouse Management SystemsAs Engines of Organizational Change,”presented by Association of ProfessionalMaterial Handling Consultants, 2:15 to3:00 p.m., Theater B.• “Rack Storage - Specification, Standards,Codes and Certification Protocols,”presented by Rack ManufacturersInstitute, 2:15 to 3:00 p.m., Theater D.If you miss a session, or can’t decidebetween two being held at the sametime, you can still view and hear thecontent later. All of the PowerPointpresentations will be captured in PDFformat and synchronized in a Flash filewith audio recordings of each session.These files will be posted to www.promatshow.com after the conclusionof ProMat.30 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

show previewwhy we have to break away from thatand see the world for where it’s reallygoing, not from where we think it is.Because the way we see the future isreally colored by everything that we’veever learned, so it’s important to startfresh and new.”After her presentation, Weiner willmoderate a panel of materials handlingand supply chain experts as they discusshow important issues, key trendsand shifts in best practices will makethe supply chain work in the future.The panel includes George Prest, CEOof MHIA; Rick Blasgen, president andCEO of the Council of Supply ChainManagement Professionals (CSCMP);Michael J. Mikitka, CEO of theWarehousing Education and ResearchCouncil (WERC); and Liz Richards,executive vice president of the MaterialHandling Equipment DistributorsAssociation (MHEDA).Educational tracksThree separate educational tracks willbe offered during the show—each havingan expanded view into a specifictopic related to materials handlingand supply chains. The tracks are progammedby:• The Association for AutomaticIdentification and Mobility (AIM),• EASE Council (Ergonomic AssistSystems and Equipment), and• Council of Supply ChainManagement Professionals (CSCMP).AIM will present a series of threespeakers discussing the use of theirmembers’ technologies. These sessionsare free to registered ProMat attendeeswithout advanced registration.“For an educational partner, ProMatprovides a terrific opportunity for usto share some just-in-time informationabout topics that our membersknow a lot about,” said Linda Young,AIM’s director of business development.“Participants will take away someinnovative ideas about how companiesare using automatic ID and mobilitytechnologies, perhaps in ways that theyhadn’t thought of before. The presenterswill share sample case studies thathave potential for use in other applicationsin different industries.”Jonathan Ludlow, author and projectmanager at Microscan, will discuss“Unit Level and Product TraceabilityUsing Data Matrix Codes: Benefits,Applications and Trends.” Ludlow willexplain the benefits of providing uniqueidentity to individual components in amanufacturing process, as well as practicalmethods of direct part marking.Patrick Noone, vice president ofsales and marketing at Woelco LabelingSolutions, will present “ImprovingROI with Automated IdentificationTechnology.” He will review the emergingtechnologies that can be combinedto facilitate automation in productidentification, as well as verification,to yield improvements in production,quality and traceability.Finally, Jason Bridwell, vice presidentof sales at Portsmith Technologies,will conclude the AIM sessions with“Mobile Computing for the AdvancedSupply Chain.” Bridwell will detail howenterprise mobile computing solutionsare impacting some of the largest globalsupply chain operations, and share howreal-time information and immediatecommunication can boost productivityand effectiveness.On Wednesday, the EASE Councilwill host “Manual Material HandlingWorkshop: Engineered Solutions forManual Handling Jobs,” with sponsorsupport from the Institute of IndustrialEngineers (IIE) and the NationalInstitute for Occupational Safety and32 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

Health (NIOSH). This workshop willprovide an opportunity to hear fromretailers, wholesalers and warehousesafety and loss prevention representativesas they participate in open paneldiscussions about the ergonomic challengesassociated with manual materialshandling jobs.“This session features a panel ofinternationally recognized experts whodesign materials handling devices,along with leading ergonomic healthand safety experts,” explained RayNiemeyer, educational services directorand EASE Council managing executiveof MHIA. “They will be exchangingideas to help find materials handlingtechnology solutions that can reduceworkers compensation claims andimprove employee performance.”Participants must register in advancefor the session, which includes a separatefee outside of ProMat registration.ProMat attendees wishing to participatecan contact Ray Niemeyer at rniemeyer@mhia.orgprior to Wednesday.Also on Wednesday, a special educationaltrack session presented by theCouncil of Supply Chain ManagementProfessionals (CSCMP) will be offeredimmediately after the keynote panel. Thispanel discussion will further elaborate onthe insights shared during the keynote.Entitled “When the Rubber Meetsthe Road…Implementing FutureVision,” the panel includes JeffStarecheski, vice president of logisticsfor Sears Logistics Services, and JohnCaltagirone, supply chain managementstrategy educator at Chicago’sLoyola University. Moderated by RichSherman, director of strategic developmentfor CSCMP, the panelists willoffer their views on how logistics andsupply chain management are evolvingto meet future business challenges.They will examine significant trendsand practices that will most impactoperations in achieving and sustainingpeak performance. MWhat is ‘The Hub’?The Hub is an interactive resource center that offersmultiple social media and informational opportunities forProMat visitors. Located in the center of the ProMat 2013show floor, The Hub will feature a social networking lounge—where attendees can catch the latest buzz about the event onTwitter, Facebook and LinkedIn. It’s also home to a wireless internet centerfor checking e-mail and networking with other attendees. Also in The Hub:details about the next Modex expo, to be held in Atlanta on March 17-20,2014 and an overview of ProMat’s Innovation Award winners.

MODERN reader surveyThe pulseon palletsFrom wood to plastic to pallet pools,our readers tell us what’s important in pallets.By Bob Trebilcock, Executive EditorAt first glance, the pallet market mayappear to evolve at the same pace asthose pre-historic looking reptiles foundon small, forgotten islands. However,between a shortage of quality used pallets,new requirements from CostcoWhat are the most important factors in your decisionsto use a certain type of pallet?Purchase priceStrengthDurabilityCustomer requirementsReusabilityCost per useAvailabilityWeightRecyclabilityCleanabilityRepairabilityEase of disposalDesign versatilityFire rating 4%13%12%11%10%22%21%35%33%38%43%49%55%63%Source: Peerless Research Group (PRG)and the introduction of a new palletpool from a consortium of ers, the past year has seen a number ofmanufacturnewdevelopments in the pallet market.Have those developments filtereddown to the manufacturers, wholesalersand retailers among Modern’s palletusingreaders? And, what moves ourreaders when it comes to pallets? Thoseare among the questions we explored inthis year’s annual pallet survey.To answer them, we surveyed e-mailsubscribers of Modern as well as a sampleof recipients of our e-newsletters.We received 672 qualified responses,defined as a reader who is employed ata location that uses pallets. Here’s whatwe learned.The who, what and how of palletsWho is using pallets, what are theyusing, and how are they using them?For starters, most respondents (58%)are involved in manufacturing, witha variety of industries represented.Wholesale distributors (17%) and retailers(6%) are also represented.The respondents represent a solidmix of large companies with revenues34 N O V E M B E R 2 0 1 2 / MODERN MATERIALS HANDLING mmh.com

Modern Materials Handling’s Pallet WebcastResults of the 2011 Pallet Usage and Trending StudyNovember 15, 2012 2 pm ET. Go to mmh.com/2012palletsWhat types of pallets do you use?exceeding $1 billion (17.5%), mid-sizecompanies with revenue of between$250 million and $999 million (12.2%)and small companies with revenuebelow $250 million (70.3%).For these users, a number of factorsgo into the decision to buy a certaintype of pallet, but the purchase priceis still the most important factor, citedby 63% of readers. The cost per use iscited by 35% of readers, suggesting thatreaders are getting more than one tripout of their pallets.Other factors include:• 55% strength• 49% durability• 43% customer requirements• 38% reusability• 33% availabilityWood pallets are still predominate.They are used by 94% of readers—nosurprise there. However, pallets manufacturedfrom alternative materialsare in the mix, with some readers alsousing:• 40% plastic pallets• 17% wood composite• 8% cardboard/corrugated• 7% metal94%Wood40%PlasticUsed, or core pallets 46%New pallets 43%17%WoodcompositeAre the wood palletsyou purchase new or used?Pallet pool 11%Using more than a year ago 46%8%Cardboard/CorrugatedWhich best describes your levelof usage for used wood palletsAbout the same 41%Using fewer than a year ago 11%7%Metal1%OtherSource: Peerless Research Group (PRG)mmh.com MODERN MATERIALS HANDLING / N O V E M B E R 2 0 1 2 35

MODERN reader surveyWhile there was a large demand forplastic pallets a few years ago followingthe introduction of a pool of plasticpallets by iGPS, demand for plastic palletsamong Modern’s readers is largelyunchanged in the last year. While 27%report they are using more plastic pallets,13% are using fewer and 60% saythere has been no change in their useof plastic.We suspect that non-wooden palletsare being used in niche applications,such as captive pallets in a manufacturingoperation, to ship back and forth toregular suppliers or customers or as aresult of a customer requirement.The 48 x 40-inch pallet is the mostcommonly used size, cited by 81% ofreaders. No surprise there either. Whatdid catch our attention was that nearly10% of respondents say they are shippingon a 24 x 20-inch half pallet. Thatis a relatively new size developed for thebeverage industry, but it may also haveapplications for end-of-aisle displays.Our readers’ pallets are circling theglobe: nearly 57% of readers say theyare shipping to both domestic andinternational customers; 39% of readersare only shipping domestically; and 4%are only shipping internationally.The leading recipient is Canada(74%), followed by Mexico/SouthAmerica/Caribbean (66%), China/Asia(57%), Western Europe (48%) andEastern Europe (36%).International business does requirea different pallet strategy for mostshippers, with only 21% reporting thatthey don’t do anything differently forinternational and domestic deliveries.Readers reported that 48% treat theirpallets; 20% use alternative materialsother than wood that don’t requiretreatment; 16% use wood pallets fromtheir own pool; and 3% use a pallet poolfor international shipments.Watch the number of treated palletsWhat has been your experienceobtaining used wood pallets?Have not experienced nor do we anticipateany issues procuring used pallets40%Quality is not as good, worse31%Fewer pallets are available21%More expensive17%Other7%By how much are used woodpallets more expensive?

Modern Materials Handling’s Pallet WebcastResults of the 2011 Pallet Usage and Trending StudyNovember 15, 2012 2 pm ET. Go to mmh.com/2012palletsin the future, especially if Canada andthe United States finally agree on a proposalto treat pallets traveling betweenthe countries in the future. That willlead to more readers treating their palletsor shipping on alternative materials.New or usedOne of the most significant changesin the pallet industry over the last twodecades has been the domination ofused wooden pallets in the 48 x 40-inchpallet market. Although precise recordsaren’t kept, some have estimated thatused pallets account for 60% or moreof that market. Modern’s readers are nodifferent, although their responses givea more nuanced view.Nearly 63% report that they rely onused pallets, also known as cores. Ofthose, 46% say they are purchasing moreused pallets than they did a year before.At the same time, 59% of readersare also using new pallets and nearly47% expect to purchase more new palletsnext year. In other words, it’s not aneither/or world when it comes to newversus used.The demand for new pallets is, at leastin part, a response to the shortage of coresthat has plagued the market in 2011.Although 40% say they have notexperienced any issues in procuringused pallets, a majority has beenimpacted. Readers report that thequality of used pallets has deteriorated(31%), that fewer pallets are available(21%) and that they have become moreexpensive (17%). Of those readers whohave experienced price increases, 55%have seen a spike of 5% to 9%, and 22%have seen a spike of from 10% to 14%.In addition to purchasing more newpallets, 22% of readers plan to createand manage their own pool of palletsor rent from a pallet pool (5%) such asthose from CHEP, PECO and iGPS tocope with the shortage of cores.Does your companyrent, plan to rent palletsor use a retrieval/recovery provider?No58%Yes, usea palletrentalcompany26%Yes,use anothertype of palletretrieval orrecovery system16%Have you evaluated orconsidered a system/solution for creatingor managing your ownpallet pool?No72% Yes28%How likely are you to considerparticipating in a palletretrieval/recovery system or ina third-party pallet rentalsystem during the next year?Notvery likely9%7%HighlylikelyIf available, how interestedwould you be in using a palletpooling service managed by thepallet industry and that wouldserve as an alternative to CHEP,PECO and iGPS?36%12%3%Highly InterestedinterestedLikely32%20%Mildlyinterested40%Not atall likelyDon't even knowwhat a palletretrieval/recoverysystem or third-partypallet rental system is30%Not veryinterested12%Source: Peerless Research Group (PRG)Not at allinterestedSource: Peerless Research Group (PRG)Block or stringerIn January 2011, Costco became thefirst retailer to require its suppliers toship product on block pallets, whichare similar in design, construction andquality to the pallets available fromCHEP, PECO and iGPS. In this survey,we wanted to see if the Costcorequirement is having an impact on thepallet market.We discovered a couple of facts.As with the new versus used question,block or stringer isn’t an either/orquestion. Yes, more than half (53%) ofmmh.com MODERN MATERIALS HANDLING / N O V E M B E R 2 0 1 2 37

MODERN reader surveyModern Materials Handling’s Pallet WebcastResults of the 2011 Pallet Usage and Trending StudyNovember 15, 2012 2 pm ET. Go to mmh.com/2012palletsreaders are shipping solely on stringerpallets and 24% are shipping solely onblock pallets. However, another 23%are shipping on block and stringer palletsin equal measure. In other words,a significant percentage (47%) is shippingsome loads on block pallets.Second, among the respondents,more than half are shipping to majorretailers, big box store operatorsand grocery store chains. Of those,33% ship to Walmart, 26% ship toCostco, 24% ship to a major grocerychain, and 21% ship to Sam’s Club.Readers are also shipping to othermajor retailers such as Target, HomeDepot, Lowe’s, Walgreens, JCPenneyand Macy’s.A significant percentage of all readers(82%) report that no customerrequired them to change the type ofpallet they were using for shipmentsin the past year. However, nearly 19%reported that they had changed theirpallet usage in response to a customerrequirement.Of those, 31% say that they are usingmore block pallets and 54% say they areusing alternatives to wooden pallets.Only 15% are using more stringer palletsin response to a customer requirement.In other words, while a relativelysmall number of respondents havebeen asked to change the type of palletthey are using, most have switchedaway from stringer pallets.Asked what type of business isrequiring them to change the type ofpallet they are using, 41% respondedthat it was a retail customer, 34% amanufacturing customer and 26% awholesale customer.For now, Costco appears to be one ofthe few companies planning to requireits suppliers to ship on block pallets.Only three readers from our surveyindicated their company was consideringa similar strategy.Are your shipments . . . . And, to which countries orregions are you shipping?International4% CanadaDomestic39%Both58%Get into the poolPallet pools have long been an alternativeto purchasing new or used pallets.That has been true whether participationin a pool involved Yes renting a pallet19%from CHEP, PECO or iGPS or a companymanaging its own assets. The latteris common 81% among auto suppliers,Nofood and beverage manufacturers, andthe pharmaceutical industry that reusesplastic pallets.Looking forward, it appears as ifmost companies plan to continue whateverstrategy they are currently pursuing.Only 17% of readers said they arelikely or highly likely to participate in apallet pool in the coming year.Of readers who would consider participatingin a pallet pool, 41% reportedthat they would explore creating ormanaging their own pool; 28% said theyhave already evaluated or consideredcreating or managing their own pool.Finally, we asked how interested arereaders in using a pallet pooling servicemanaged by the pallet industry as analternative to established pools managedby CHEP, PECO and iGPS.Roughly 14% indicated they areMexico, South America,CaribbeanChina, Japan, SE Asia,North Asia and AustraliaWestern EuropeEastern EuropeMiddle East, North AfricaIndia and SubcontinentSouth AfricaOther17%27%26%8%36%48%57%66%74%Source: Peerless Research Group (PRG)A major retailer recentlyswitched from acceptingstringer pallets and is nowrequiring distributors touse block pallets. Is yourcompany planning asimilar strategy?Unsure of whatwe’ll do yetNo63%10%Yes8%Haven’theardanythingabout this58%Source: Peerless Research Group (PRG)interested or highly interested. And,66% indicated that they are not very ornot at all interested.That could indicate that the palletindustry needs to do more work toeducate readers on what it may offerand how they may benefit from a newpool. 38 N O V E M B E R 2 0 1 2 / MODERN MATERIALS HANDLING mmh.com

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MODERN equipment reportSupply chain software:Should Iupgrade myWMS?Once the cobwebs of a legacy WMShave been cleared, it’s easier thanever for customers to stay current andcompetitive without breaking the bank.By Josh Bond, Associate EditorUpgrading a warehouse managementsystem (WMS), whether to a new versionor a new implementation, can bea major event. It’s no wonder why enduserstypically procure a base WMSand work with it for eight to 10 years,performing minor version upgradesevery three to five years along the way.End-users can’t be faulted for spendingthose years modifying a system tosuit their needs or postponing upgradesif they don’t see the value. However,there is a downside to those modificationsand delays. When the time comesto add functionality, the existing systemcan be so aged or homegrown that evenrelatively simple improvements becomecostly and time-consuming.The customer is then comfortablewith a system, only to find it has suddenlybecome an impediment.However, the process of fine-tuninga WMS to stay current, add functionality,and stay competitive might notrequire the prolonged investment it dideven five years ago.“Now you can upgrade and switchit on fairly painlessly,” says John Hill,director at St. Onge. “In the old days,that wasn’t possible. You were going tohave to bring in a supplier for a majorimplementation.”Customers with aging systems mightstill find the process of modernizingdifficult and costly. But once the cobwebshave been cleared, end-users withmodern implementations will significantlyreduce the risk of customizingthemselves into a corner.How can companies know when it’stime to upgrade? The short answer is:The sooner the better. Whether they’relooking to improve existing processes,make more efficient use of IT resources,or keep an eye toward future capabilities,an up-to-date WMS will grant businessesthe nimbleness to seize opportunities.Is it time?Most WMS end-users upgrade aboutevery 3.5 years, while most reputablesuppliers offer updates on an annualbasis, says Hill. These updates aretypically little more than new versions40 N O V E M B E R 2 0 1 2 / MODERN MATERIALS HANDLING mmh.com

with small adjustments to the system.They are distinct from an upgradeinvolving increased functionality suchas voice or a labor management module,or a change-out event such as anew WMS implementation or supplier.That said, upgrading an old WMScan look very much like a new implementation,according to Tom Kozenski,vice president of product strategyat RedPrairie. Aside from businessexpansion, a few key reasons could justifyan upgrade, Kozenski says. If thetechnical underpinnings—the server,the database or the layered products—are going out of support, a customercan reduce future maintenance costsby upgrading.Many companies are proactivelyinstalling the capability to comply withinitiatives like e-pedigree in the pharmaceuticalmarket or the product traceabilityinitiative (PTI) in food handling.In these cases, a company reduces risk,says Kozenski, and can use that as a differentiatorto win new business.Softer compliance pressures canalso come into play, according to ChadCollins, chief marketing officer forAccellos. For example, a large retailermight require pallets from smaller suppliersbe configured and labeled a certainway. “Those compliance requirementsdrive small- and mid-sizedbusinesses to adopt or update WMS,”says Collins. “Retailers continue to beaggressive about squeezing cost outof their overall supply chain and thatcomes back to their suppliers meetingthose requirements.”The benefits of a WMS go beyondlabeling pallets, but that doesn’t stopcustomers from implementing themto address isolated needs. A wiserapproach, says Collins, is to considerthe benefit to each application in thewarehouse. “If a customer is going toupgrade, they will be better off if theyuse it as an opportunity to re-evaluatebusiness processes.”What should I look for?The market has matured to the pointthat solutions to these challenges aremmh.com MODERN MATERIALS HANDLING / N O V E M B E R 2 0 1 2 41

MODERN equipment report“ If a customer is going to upgrade, they will bebetter off if they use it as an opportunity tore-evaluate business processes.”—Chad Collins, chief marketing officer for Accellosnot well-kept secrets. In fact, accordingto Kozenski, “Customers expect everythingto be in there. They want it allintegrated, they want a single architecture,and they don’t want to do bolt-onsanymore.”Before any outlay, an end-usershould look deeper into the capabilitiesof its current WMS. For instance,some end-users like to continue todo directed putaway manually, saysCollins, and others continue to usepaper rather than scanners at the pointof picking and shipping.Not only are many end-users notfully using their WMS, it may be thelimiting factor for fuller use of currentequipment. For example, if 80%of associates on the floor are usingmobile handheld terminals, says EricLamphier, senior director of projectmanagement for Manhattan Associates,upgrading that technology can makethose terminals more intuitive and theassociates more productive.Many have yet to fully use coreWMS functionality, says Hill, but othershave deliberately postponed usingadd-on modules. There is a certainstrategic benefit to being future-proof,says Hill, acknowledging that featurespurchased at one time might notbe needed until a later one. In fact,although an upgrade might be a goodtime to implement a new module, orvice versa, most agree it is wise to takeone thing at a time. It might take aslong as a year to fully acclimate tothe core WMS, or to add on modulessuch as labor management.Any added functionality will requirea strong relationship between operationsand IT staff, says Hill. The two groupsshould work closely to ensure a successfuldeployment. Lamphier agrees. “If theinitiative is too heavily biased and ledby one half of the company, either ITor operations, and the other half doesn’thave a strong seat at the table and aninvestment in the outcomes, that’s arecipe for disaster,” he says.What’s new?New WMS products are much fasterand more intuitive, process greatervolumes of data, and require lesshardware and less cost, accordingto Lamphier. Not only are they lessexpensive to deploy, but new systemsare easier to maintain.“Across the board, it has gottena lot easier to upgrade and stay currentthan in years prior,” says ChuckFuerst, director of product strategy forHighJump Software. “With more modernversions, work flow modificationstailored for the customer’s environmentare separated from the underlying technology,”he says. “We can pull that outand slide a new one in without havingto re-architect anything they’ve done onthe business process layer.”Integration with the enterpriseresource planning (ERP) and downstreamintegration with automationequipment and conveyance systems ismuch easier, says Lamphier. “Ten yearsago those integrations would have beencompletely customized,” he says. “Nowit’s data-driven and that has driven downthe cost of integration significantly.”These advances will allow upgradesto be performed more frequently in thefuture. “The WMS of today are muchWith interleaved task management, an up-to-date WMS can keep workersproductive for more of each day.42 N O V E M B E R 2 0 1 2 / MODERN MATERIALS HANDLING mmh.com

Grow your business byleveraging market intelligence.Transportation Management SystemsMeeting the Challenges and Obtaining ResultsThe Adoption and Usageof Picking Solutionsin Materials HandlingOperationsDoes Voice TechnologyLive Up to Its Promise?Sponsored by: Conducted by:On behalf of:Transportation Management SystemsMeeting the Challenges and Obtaining ResultsJanuary 2011Peerless Research Group offers awide range of custom and proprietaryresearch solutions to businesses,consultants and advertising agenciesspecializing in supply chain, logistics andmaterials handling products and services.We offer a complete set of quantitativeand qualitative services and techniquescovering Internet and telephonemethodologies as well as focus groups,one-to-one interviewing.Custom or proprietary studies includebrand awareness, product and servicesusage and buying intentions, brandequity, corporate image and perception,advertising concept testing, productfeasibility studies, market surveys,customer satisfaction research as well ascorporate management studies.A Peerless Media Company111 Speen Street, Framingham, MA 01701Phone: (508) 663-1500www.PeerlessResearchGroup.com

MODERN equipment reportmore functionally rich than those offive or six years ago,” says Kozenski.“Any or all of the modifications thecustomer did five to 10 years ago theywill likely find in the core producttoday. Upgrades going forward will beeasier without having to account formodifications.”Slotting and interleaved task managementhave been available in Tier1 WMS packages for years, says Hill,but they are increasingly integratedinto core WMS packages for customersin Tiers 2 and 3. Many currentofferings also have integrated parcelshipping, which was not present inolder versions.Collins says the most popular WMSadd-on products are business intelligencemodules that help establish keyperformance indicators, metrics andreporting capabilities that reside ontop of the data. The shipping moduleis also popular and allows customersto add parcel shipping and less thantruckload (LTL) directly to the WMS.The ability to manage transportationrates and coordinate carriers is popularfor direct-to-consumer distributionand customers with smaller products,says Collins.Should I go into the cloud?The newest and fastest-growing segmentis the option of a cloud-basedWMS deployment. “Cloud is still theminority of deployments, but thereis increasing interest,” says Collins.“We’ve gone from maybe 5% of newA modern WMS can help ensure suppliers comply with customer requirementsand win new business.customers asking about cloud to now40% to 50%.”By significantly reducing the maintenanceand labor costs associated withon-site software, hardware and IT supportstaff, cloud-based options havetraditionally served smaller customerswho could not otherwise afford oreffectively manage a WMS. Even somelongtime users of on-premise deploymentshave migrated to the cloud.“It was a little surprising to see thenumber of larger enterprise customersthat were interested in the cloud, saysFuerst. “From their perspective, it wasmore of a strategic decision to reducetheir overall IT footprint. Managing hardware,software, patches, upgrades and thenetwork were not core to their business.They wanted to focus their IT resourceson more customer-facing projects.”RedPrairie’s Kozenski says manycustomers with centralized on-premisedeployments are essentially alreadyworking in the cloud—with a few keydifferences. “We can virtualize the customer’sservers and throw processingpower at a problem during peak andthen take it back when the volume isgone,” says Kozenski. “We can makethose decisions in the same day. Whenthey own their own servers, they can’tdo that as quickly or as cheaply.”Security and network latency are“ Any or all of the modifications the customer did fiveto 10 years ago they will likely find in the core producttoday. “—Tom Kozenski, vice president of productstrategy at RedPrairie44 N O V E M B E R 2 0 1 2 / MODERN MATERIALS HANDLING mmh.com

A cloud-based WMS grants remotevisibility into a network, facility, zoneor worker.the top concerns for prospective cloudcustomers, but Kozenski says both areminor issues. He emphasized that acustomer’s centralized WMS and asupplier-hosted WMS have virtuallyidentical security risks. What’s morepressing is the customer’s desire to havecontrol over upgrade cycles, he says.Customers prefer not to be running ona shared instance of software so theyand 10 competitors are upgraded at thesame time. “In a multi-tenant environment,there is no modification, thereis only configuration,” says Kozenski.“This might limit your ability to developcompetitive advantages.”Whatever a company’s concerns andgoals, the best way for end-users toensure they are working with an optimalWMS is to maintain a good relationshipwith their suppliers. “Althoughthey might not think they’re ready toupgrade,” says Kozenski, “they shouldstay in touch with their software providerregularly.”After all, says Hill: “Suppliersaren’t keeping updates secret.” Companies mentionedin this articleAccellos, accellos.comHighJump, highjump.comManhattan Associates, manh.comRedPrairie, redprairie.comSt. Onge Company, stonge.comPROTECH ® Precision PalletsThe SAFE Choicefor Every Industry• Top-quality 40” x 48” pallets• Easy-to-clean hygienic design• Will not trap water• Mold- and insect-resistant• 4-way forklift & jack entry• Superior strength-to-weight ratio vs. wood• Impact absorption protects your freight• Molded, one-piece design for added durability• Optional intermittent lipNow Available: Fire-Retardant Protech 4048 –both decaBDE-free and FM Approved866-713-9446www.tmfcorporation.comwww.protech-pallet.comWWW.TRANSBOTICS.COMmmh.com MODERN MATERIALS HANDLING / N O V E M B E R 2 0 1 2 45

modern productivity solutionAutomation improvesprocess flowAiming to reduce manual tasks, companyreaps unexpected productivity improvements.By Josh Bond, Associate Editormajor automotive manufacturer wanted toA minimize manual traffic in its aisles throughincreased automation. After deploying automaticguided carts (AGCs), the customer also improvedthe overall flow of material movement, optimizedorder management, and reduced risk of damage—all while minimizing disruptions duringimplementation with a design platform for futureexpansion.The goal was to provide a safe working environmentthrough automation while increasing efficiencyand keeping costs low. The company wanted tomove its carts of shocks and trim parts within theplant, but without lift trucks. The company selecteda series of AGC tuggers (Transbotics, transbotics.com) to carry the loads securely and reduce costs.“Some of the most important benefits of this systemhave been the reduced walking time and overallreduction in manual tasks,” says the facility's plantengineer. “Our biggest concern at the outset wasthe possibility of a collision with a lift truck. Oncethe drivers became familiar with the carts' safetyfeatures and accustomed to having them around,we've had no problems.”The system consists of one tape-guided jackpin tugger AGC that transports three of the cartsthroughout the layout. The AGC tows carts withshocks and trim parts from the picking area to thepre-assembly line. There’s a turnaround and a workstationat each end of the guide path.The system also includes another dedicatedAGC to pick up shocks from the unloading docksto the shock picking area. This design provides anexpandable platform that meets current and future46 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

assembly needs. The AGCs use a magnetic tape navigationtechnology and controls platforms.The result is an expandable, capable system that providessafety and efficiency with minimal disruption duringimplementation. The low-cost solution enabled the companyto keep its retail prices stable and margins higher.The company is now evaluating other areas in its operationwhere automated solutions might be deployed.AGVs keep productmovingaroundthe clockPackaging manufacturer’sflexible new fleet helpsrepetitive tasks becomeefficient and safe.Schur, a global manufacturer of packaging materials,machines and systems, wanted to improve theergonomic environment for workers in its Denmarkfacility by automating repetitive movements. Byinstalling an automatic guided vehicles (AGV) system,the company improved flexibility, efficiency,safety and productivity.At the end of the production line, finished corrugatedboxes are stacked on pallets. Full pallets arefirst moved to an automated strapping and wrappingmachine and then moved to the warehouse for storage.Empty pallets are moved from a pallet-stackingmachine and delivered to the palletizers. There arefour different types of pallets depending on the productand the export destination.Before the AGV installation, movement of the fullpallets to the strapping/wrapping machine and tothe warehouse was done using manual forklifts. Theprocess was repetitive and predictable—a great candidatefor automation. Shur installed four compactfork-over style AGVs (JBT Corp., jbtc.com).“The most important benefits of the new systemare its stability, accuracy and the smooth work flowit enables,” says Allan Laursen, production managerat Schurpack Denmark. The AGVs now moveraw materials from bulk storage to the productionmachines. One added operation was for the AGVsto move pallets to storage and place them into storagelanes thus avoiding the need for overnight forkliftoperators. The AGVs can also collect and storepallets post press, buffering them for secondaryoperations use.The system is easy to reconfigure and can be expandedby simply adding more vehicles. The predicableoperation, accurate navigation, smooth acceleration/deceleration, non-contact safety bumpers, and visualand audible warning signals gave workers confidencethat the AGVs would improve safety.“We involved a big group of people in the project,”says Laursen. “This gave them a sense of ownership,but also ensured that they were comfortablewith the system.”Because of this success, productivity at the facilityhas increased 12%. These AGVs will operate inthe printing department transporting full palletsfrom a pile turner conveyor to one of two presses.They will also transport empty pallet stacks fromconveyors to storage areas or the point of use. Mmmh.com Modern Materials Handling / N o v e m b e r 2 0 1 2 47

A special supplement to:2012 Warehouse/DC Operations Survey:Mixed signalsA record response reveals that readership is divided interms of investment: One side remains cautious, whilethe other is on the verge of making significantchanges to their warehouse/DC operations.By Maida Napolitano, Contributing EditorAfter years of slow economicprogress, the results ofthe Supply Chain Group’s2012 Warehouse and DistributionCenter (DC)Operations Survey show two schoolsof thought emerging from the ashes:There are those companies that remaincautious, staying conventional withminimal plans for expansion; and thereare those on the verge of making significantinvestments and changes to theirdistribution operations.Designed to gauge activities andtrends in warehousing and DCs, ourannual survey offers a first-hand lookinto the state of today’s DC and warehouseoperations. In September, a surveyquestionnaire was sent via emailinvitation to Supply Chain Groupsubscribers. The survey gleaned 805qualified responses (a new record forthis survey) from upper-level managersto CEOs—all personally involvedin decisions regarding their company’swarehouse and DC operations.Most participating companies camefrom manufacturing (44%), followed bydistributors (28%), third-party providers(9%) and retailers (8%). An assortmentof products handled in the DC wasonce again well-represented with foodand grocery leading the pack at 11%,followed by industrial/chemical at 10%,and electronics and building materials,tied for third, at 8% each.This year’s findings revealed mixedsignals coming from opposite ends ofthe spectrum. About 52% of respondentsare adopting a more cautiousapproach, spending less than $250,000for warehousing equipment and technologyin 2012.“That’s a predominant statistic,”says Norm Saenz, senior vice presidentand principal of TranSystems, asupply chain consulting firm and ourpartner for this survey. “It supportshow tough economic times have controlledspending to less than $250,000for a majority of respondents. That’sonly good for minor improvementsto operations, such as racking or thepurchase of a lift truck, versus openinga new facility or implementing newtechnologies.”48 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

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2012 Warehouse/DC Operations Survey WebcastJoin Kicker our Kicker research team as they dig into all the findings in detail.Thursday, November 29 @ 2:00 p.m. ETGo to mmh.com/WDCbenchmarksurveySize of distribution center networkNumber of buildingsBY Name, TITLETotal square footageMore thanthree buildingsThreebuildingsTwobuildingsOnebuilding36%13%17%34%31%21%6 or morebuildings14%18%37%Less than50,00050,000-99,999100,000-249,999250,000-499,999500,000-999,9991,000,000-1,999,99918%21%13%16%15%13%12%12%7%7%2,000,000+ 10%9%25%22%2011201220112012Clear height of buildings42%20%26%8%4%Less than20 feet20-29 feet30-39 feet40-49 feetMore than50 feetSource: Peerless Research Group (PRG)50 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

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2012 Warehouse/DC Operations Survey WebcastJoin our research team as they dig into all the findings in detail.Thursday, November 29 @ 2:00 p.m. ETGo to mmh.com/WDCbenchmarksurveyScope of distribution center operationsAnnual inventory turns Number of SKUs2%4%Less than 1.01.0 to 2.93.0 to 4.95.0 to 6.97.0 to 8.99.0 to 11.912.0 to 17.918.0 to 23.924.0 or greaterAverageAreas of service15% 15%Singlemetropolitanarea12%15%27%24%19%16%11%11%7%9%11%9%2%4%9%8%8.28.223%21%Multi-stateregionHowever, Don Derewecki,senior management consultantalso from TranSystems,prefers to focus on the otherend of the spectrum: those17% of respondents who arespending $1 million or morethis year, and another 16%planning to spend that sameamount next year.“That’s for significantprojects—an indicator thatcompanies are doing morethan just replacing worn outequipment,” says Derewecki.4% 5%Half ofthe U.S.Less than 1008%16%100 to 49913%14%500 to 9999%12%1,000 to 2,49912%13%2,500 to 4,99913%12%5,000 to 9,99911%9%10,000 to 19,99912%8%20,000 to 49,99911%7%50,000 – 74,99975,000 or more29%26%Entire U.S.Type of business36%44%Manufacturer28%26%Distributor4%2%8%7%5% 4%WesternHemisphere20112012Source: Peerless Research Group (PRG)15%3PL9%“These stronger companies have diligentmanagers who have probably beencontinuously shaving points off theiroperating costs over the past few years.By now all the low hanging fruit is gone,so they’re starting to get more aggressiveand finally looking to squeeze thetrigger on investments in mechanizationand automation.”Over the next few pages, we’ll diginto the high-level findings of the 2012Warehouse and Distribution Center(DC) Operations Survey to share moredetail on how the warehousing and distributionlandscape has changed overthe past year. This year we’ve updatedportions of the survey to capture emergingtrends while continuing to trackthe critical measures of warehousingactivities we’ve charted over the pastsix years. Let’s see how your operationscompare to what your peers are doinginside the four walls.What’s trending?Despite the mixed signals, there’s oneclear conclusion that both Derewecki28% and Saenz derived from this year’s survey:Corporate is making its presence26%felt inside the warehouse and DC.“There’s an increasing recognition ofthe importance of the supply chain andhow much money is being spent on it,”Global says Derewecki. “Corporate managershave become increasingly focused onthe details that make the difference,even at the DC level.”According to Saenz, this fact is nevermore evident than in the numberof respondents who saythey’re using their enterpriseresource planning (ERP) system’swarehouse management20112012 system (WMS) functionallyin the DC (27%)—twice thenumber of respondents usingbest-of-breed WMS (13%).13%“Corporate does not want to9% 10% 10%play around with expensiveWMS packages,” speculatesRetailer OtherSaenz. “They made a commitmentto use an ERP system,so they want to use everythingSource: Peerless Research Group (PRG)52 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

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2012 Warehouse/DC Operations Survey WebcastJoin our research team as they dig into all the findings in detail.Thursday, November 29 @ 2:00 p.m. ETGo to mmh.com/WDCbenchmarksurveythese systems can offer—even thoughit may not be the best thing for thewarehouse.”Derewecki agrees, adding that theWMS being offered today by the bigERP players “isn’t as bad for the warehouseas it used to be.” He says that10 years ago some of his clients wereforced to use ERP at the DC levelbecause corporate wanted everyoneto integrate with the company’s ERPsystem. “All of the functionalities thatmanagers used to have with their standaloneWMS just weren’t there,” saysDerewecki. “In some cases, they hadto switch back to more manual operations.”But these days, he adds, developershave significantly improved thefunctionality of ERP’s WMS packages.“As more companies run their businesseswith an ERP system, it’s easierand less costly to simply use that ERP’sWMS,” adds Saenz. “I think this is atrend that’s going to continue.”There’s also a trend toward a moreconsolidated network. Since 2010, thepercentage of respondents with threeor fewer buildings has beenActions taken to lower DC operating costsTaken any action 95%92%Improving warehouse processes64%77%Improving inventory control 60%61%Changing rack/layout configuration48%41%Reducing staff 48%37%Improving warehouseinformation technologyNumber of employees1,000+500 to 999400-499300 or more200 to 299100 to 19950 to 9925 to 49Less than 25Average numberof employees40%32%Renegotiating leases 27%25%Other 3%3%Using 3PL 14%11%2011201212%5%3%5%8%19%13%13%25%300+25%12%5%3%5%8%13%12%15%29%2011 2012252 239Source: Peerless Research Group (PRG)Source: Peerless Research Group (PRG)steadily increasing, while thepercentage with four or morebuildings has been steadilydecreasing. Saenz believesthat it’s all part of a continuingpush by companies to domore with less.“However, with fewer facilities,you may achieve savingsin operating costs, but youmay be potentially increasingyour freight,” Saenz cautions.“This is not a particularlygood move with today’s inflatinggasoline prices.”Even more mixed signalssurface from this year’sfindings. While some networksmay be contracting tofewer facilities, about 60% ofrespondents are planning todo some sort of expansion thisyear. Twenty-six percent areincreasing their number ofSKUs, and 25% are increasingthe number of employees.Despite these plans for expansion,average inventory turns have notimproved and remain steady at 8.2.Derewecki offers a possible explanation:“At many companies, in spite ofthe emphasis on inventory control andthe improvement in information systemstools, the proliferation of SKUshas prevented the overall turn ratiosfrom improving.”300+25%The multi-channel effectFor the first time, wedecided to track how companiesuse market channels—orhow they makeproduct available to theircustomers.Most of the respondents(84%) report servicingmore than one channel:67% report shippingto wholesalers; 57% toretailers; and 29% aree-commerce based, shippingproducts directly tocustomers.“I would be most interestedin tracking e-commercepenetration overthe coming years,” saysDerewecki. “It seems thatdespite what industry ourclients are in, if they arenot using the Internet54 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

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2012 Warehouse/DC Operations Survey WebcastJoin our research team as they dig into all the findings in detail.Thursday, November 29 @ 2:00 p.m. ETGo to mmh.com/WDCbenchmarksurveynow, they have a plan to get into it.”He notes that more consumers are nowusing brick-and-mortar stores merely as“showrooms” to see a particular model,confirm its looks and functions, butthen head back home to compare costsamong web retailers before ordering thatmodel online.How are multi-channel respondentsfulfilling their orders? Forty percent arefilling their orders themselves from onemain DC, designating separate areasfor retail or e-commerce or schedulingspecific pick waves for certain channels.“Almost 25% of respondents havealready decided to put it in a separateDC,” notes Saenz. “It would be interestingto see how these results changeas each channel grows. I predict moreseparate DCs and the use of morethird-party logistics providers.”2012 DC network profileThe profile of this year’s distributionnetwork remains mostly the same asthe past few years.Sixty percent of respondents operateless than 250,000 square feet ofspace in their distribution network,with most common clear heights of 20to 29 feet. Derewecki predicts that,over time, the mix is going to shifttoward taller, higher buildings. “Lifttruck technology is making higherbuildings very practical,” he says.“Newer, double-deep reach trucks, forexample, can lift to a height of over 36feet.”Seventy percent of respondentsreport undertaking some kind of distributionnetwork optimization and locationstudies, mostly on an “as-needed”basis. As a result of these studies, halfof respondents (50%) report “movinginventory among warehouses” asit is the easiest and quickest optionamong all the other network improvementactions. For those adding DCsas a result of these studies, most cite“improved customer service” (70%)and “the penetration of new markets”(36% ) as their top two drivers.Materials handling systems in useReceivingConventional receiving 89%85%Mechanized (conveyor-based)receiving12%13%PickingConventional picking 80%74%Mechanized (conveyor-based)pickingAutomated picking15%8%9%8%ReplenishmentConventional replenishment 69%63%Automated replenishment 10%9%Mechanized (conveyor-based)replenishment9%8%Conventional storageAutomated storage and retrievalAutomatic guided vehiclesOther8%8%6%5%3%2%Tracking previous trendsRecycling continues to dominate sustainabilityefforts at 76%. This yearhowever, slightly more respondentsare “reusing shipping containers” and“using metal and/or plastic pallets.”Derewecki notes that he’s seeingmore plastic pallets in use at pharmaceuticalmanufacturing because of FDArequirements. “Wherever you have arequirement of a sterile or cleanroomenvironment, then that’s one good wayyou can use reusable plastic pallets.”Fortunately, fewer respondents (only15% versus last year’s 28%) experiencedcatastrophic events this year comparedto last year. Open-ended responses showmany operations being hit by hurricanesand tornadoes; but to protect againstthese particular threats, survey takershave installed back-up generator and2011201285%82%Source: Peerless Research Group (PRG)data retrieval systems, set plans in placeto re-route demand to another DC, andhave established multiple sources forparts and raw materials.To reduce operating costs, “improvingwarehouse processes” (64%) and“improving inventory control” (61%)remains the top two actions preferredmost by respondents. “It makessense because both do not necessarilyinvolve a high level of investment,” saysDerewecki. “However, the better operatorshave already done all the processimprovements that they can do withoutmaking capital investments. They areat the next stage. To improve, they mayneed to invest in mechanization andautomation.”Maida Napolitano is a ContributingEditor to Modern Materials Handling56 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

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FOCUS ON Automated storageScalable staging bufferdelivers operationalflexibilityTo support goods-to-person order fulfillment,pick-face replenishment, palletizingand production buffering, the Multishuttleflexible staging solution consists ofmultiple levels of rack structure, carriervehicles, conveyor and software. Eachlevel of the rack includes a carrier vehiclethat travels horizontally to access loadsstored in totes or trays by an extractiondevice. Flexible, the system fits into overheadspaces or under and over obstructionsfor maximum cube utilization. Formanual back-up picking, work platforms inthe rack aisles allow access to stock. Thesimplicity of the modular carrier vehiclesallows high system uptime, system redundancy,low power consumption and quietoperation. Dematic, 877-725-7500, www.dematic.us.Mini-load AS/RS connectedto pick-to-tote workstationsFor ongoing management of increasingorder volumes, an automatic Mini-loadautomated storage and retrieval systemwith connected order picking stationshandles small parts orders. Capable ofstoring in excess of 44,000 differentitems, the system uses 32,000 totes andincludes eight single-mast cranes traveling23 feet per second with lifting speedsof 13 feet per second for throughputof 137 totes per hour each. Equippedwith telescopic load-handling devices,the system provides double-deep storageof totes weighing up to 55 pounds.For order creation, totes are retrievedin order-related sequence, then deliveredby a short conveyor section to fourdirectly connected pick-to-tote pickingstations, enabling a supply and removalbuffer of up to 25 totes per station forretrieval and storage. SSI Schaefer, 800-876-6000, www.ssi-schaefer.us.Heavy-duty vertical carouselCapable of holding up to 1,433 poundsper carrier, the Megamat RS Model 650vertical carousel can handle a total unitload of 41,887 pounds. The carouselcomes in a variety of widths up to 13 feet,depths to 5.62 feet, and heights to 32.85feet. Carriers can be equipped with inserts,rollout drawers, intermediate shelves,partitions, dividers and specialty holdersto create an ergonomic solution for storingand retrieving heavy parts. With the pushof a button, carriers within the enclosedunit rotate around vertically to deliverstored goods to the operator throughone or more ergonomic access openings.Working on the goods-to-personconcept, the machine eliminates the walkand search time associated with standardshelving. Kardex Remstar, 800-639-5805,www.kardexremstar.com.Space-saving storagesystem for cartons andcontainersCapable of managing a large number ofvarious sized containers, trays, cartonsand carrier units, the OSR Shuttle operatesin multiple areas of a warehouse,unifying several applications into onesystem. One unit can function simultaneouslyas a storage warehouse, goods-inbuffer, picking buffer, consolidationand dispatch warehouse and dispatchsorting rack. The system offers up toquadruple-deep storage in floored racksand interfaces with a range of differentstorage units, including as straight-sidedcontainers, collapsible crates, taperedboxes, nest and stack containers andcartons. All processes—including storage,consolidation, sequencing, buffering,picking and handling of returns—canbe executed with the device. KnappLogistics Automation, 888-606-0695,www.knapp.com.58 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

FOCUS ON Automated storageAutomated verticalsmall parts storageFor secure, space-saving small parts andtool storage, the SPSS vertical storagesystem provides faster, more efficientpicking, storageand inventorymanagementby combiningorganization andprotection withmodular drawerstorage. Eachtray holds up to500 pounds. Features include a choice ofstandard controls or an optional inventorycontrol software package for applicationsrequiring inventory control, communicationto host, connection to peripheralhardware or control of multiple machines.The machine includes a welded lowerbase module and bolted construction inthe upper frame for increased durabilityand shorter installation time. Offered inheights from 12.5 to 40 feet, quick shipmodels come in 18, 24.5 and 31 feetheights. Lauyans & Co., 502-774-2200www.spssonline.com.Robotic, gantry-basedbeverage case pickingA large-scale robotic case and layer pickingsystem for beverage handling accommodateshigh-volume, high-SKU distributiondemands. The system coordinatesautomated storage/retrieval systems,conveyor and multiple robotic gantriesto systematically pick products in singlesor groups. Picks are sent to the dockface in an optimized trailer load or palletizingsequence. Distribution efficiency isenhanced by labor savings and error-freepicking. Compact, the storage spaceunder the gantry ensures higher processingrates per square foot without fixedinfrastructure such as racking or shelving.For traceability, the system providesprecise information on the location of allproducts, as well as the ability to isolateSKUs in the event of a problem or recall.RMT Robotics, 905-643-9700, www.rmtrobotics.com.Laser-pointing pick-to-lightintegrated into VLMCombining a laser-pointing pick-to-lightsystem with a vertical lift module, the newLaserViper system improves order pickingaccuracy and productivity. The pointingsystem is located in the pick window ofthe VLM. It identifies items to be pickedwith a red dot, eliminating miss-picks. Thesystem can pinpoint inventory as smallas a fraction of an inch, allowing itemssuch as vials, fasteners and small boxesof inventory to be located immediately.Because the system eliminates light barsand indicators that operators have to readbefore manually locating a stored item ina tray, it also provides higher tray storagedensity. Sapient Automation, 888-451-9711, www.getsapient.com.High-performance shuttleinterfaces with multiple loadhandling devicesIdeal for highly dynamic storage and bufferapplications, the Stingray shuttle featuresfunctionally separated travel and liftaxes for higher throughput performancethan stacker cranes, enabling capacityand performance scalability. Operatorscan vary the number of shuttles deployed,as well as change the configuration oftote and shuttle lifts. For lower performancerequirement systems, shuttles canchange levels with a shuttle lift. Because itinterfaces with a variety of load handlingdevices, the shuttle handles totes, cartonsand similar load carriers in single ormulti-deep racks. Lightweight constructionoptimizes energy efficiency with highacceleration and speed with reducedpower consumption. For easy maintenance,quick-release fasteners providetool-free access to the shuttle, while maintenanceplatforms are arranged every8 feet for access without disrupting thesystem. TGW Systems, 231-798-4547,www.tgw-group.com.Storage and retrievalsystem handles multiplecontainer sizesTo permit flexible handling of smallerbatch sizes and increased productdiversity, the 2/4-deep storage systeminterfaces with different container sizesfor greater agility in automated smallparts storage facilities with multiple-deepstorage. The system can handle containersmeasuring 23.6 x 15.6 inches (600 x400 millimeters) and 11.8 x 15.8 inches(300 x 400 millimeters) in any combination.Goods can be stored without beingpresorted by storage unit size, and theretrieval machine has flexible accessto each load unit for series formation.Because of the load handling device’s60 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

capacity, containers do not have to bedivided into modules. Order pickingaccuracy improves because only thecorrect article is accessed with fewermachine movements for longer maintenanceintervals. viastore systems, 855-539-8895, www.us.viastore.com.effective use of open spaces under floorsand under roofs, the Clean Mini StockerCMS-50 mini-load AS/RS minimizes theoccupation space within the cleanroom. Italso meets Class 1 cleanroom standardsand operates at an average cycle timeof 15 seconds. Daifuku Webb, 248-553-1000, www.diafukuwebb.com.AutomatedVerticalStorage SystemsIt All Adds UpTo VALUEAS/RS for cleanroomstorage applicationsTwo automated storage and retrievalsystems are offered for use in cleanroomtransport and storage applications,including semiconductor and flat-panelLCD and plasma display production. TheClean Stocker CLS-50 buffers intrabayand interbay work in progress with locationmodules that can be expanded asrequired. Featuring an average cycle of14 seconds, the AS/RS may be specifiedwith a non-contact power supply to meetClass 1 cleanroom standards. MakingLooking for moreautomated storageproducts?Search our databaseat mhpn.commmh.comHandle rolls, slings, spoolsConstructed with two side frames andequipped with vertically guided chains,the Clasimat Basic carousel moduleshave simple universal structures suitablefor future expansion. Using a toothedcrown wheel to move its two lateral chainloops, the motor rotates the trays like adumbwaiter. Its simple operation allowspersonnel to use it without having to keyin sophisticated instructions. Operatorsenter a code, push one button, and themachine trolleys the requested item tothe removal areaor picking level.Adaptable, theequipment is idealfor handling rolls,slings, tires, garments,spools ortrays of differentsizes and capacities.InterlakeMecalux, 877-632-2589, www.interlakemecalux.com.www.mhpn.com/producttopic/category/storageSmall parts are expensive. Traditionalshelving eats up valuable ß oor spaceand exposes parts. WhatÕs more, partscan be tough to Þ nd and reach; keepingaccurate inventories a challenge.The Lauyans Small Parts StorageSystem (SPSS) is a USA manufacturedsolution offering high density storageutilizing vertical space for greaterfootprint capacity, worker safety,security, labor savings and the mostcompetitive pricing available.Before you decide to buy anyAutomated Storage System, go onlineand check out our pricing.www.SPSSonline.comIt All Adds Up To VALUELauyans & Company, Inc.1-866-LAUYANS (528-9267)USA Manufactured

Efficient.Productive.Safe.Increase your order pickingproductivity and minimizeworkplace injuries with PalletDispensers from Cherry’s.• Quick, no-touch pallet handling forpick operators.• High speed dispenser: dispenses apallet/s to the ground every 10 seconds.• Dispenses GMA, stringer, rental, plastic,aluminum, export and two-way pallets.• Single deep and double deep models.Capacity: 40 pallets and 80 pallets• Organize & maximize warehouse spaceby centralizing empty pallet storage.800-350-0011PalletDispenser.com600 Morse Ave. Elk Grove Village, IL Product ShowcasePrintlabels fromcompact,streamlinedfootprintThe ZT200 tabletopindustriallabel printer seriesboasts a streamlined form and compact footprint to fit intotight spaces. Backwards compatible, the printer can be maintainedwithout tools and is easy to use with minimal operationtraining. Two models are offered for quick installation andintegration into existing operations: the ZT220 has high impactpolymer case and simple single-use three button interface forsimpler applications; the ZT230 sports a durable metal frameand cover with an icon-based LCD graphical user interface andlarger ribbon capacity. Zebra Technologies, 866-230-9494,www.zebra.com.Dual tamp label printer/applicatorCapable of printing and applying labels to two adjacent cartonor product surfaces, the PA1200DT dual tamp label printer/applicatorcan be configured to apply labels to front andside, front and top or front only. Using the supplier’s H-Seriesthermal/thermal transfer printers, the device produces printresolutions of 203 or 300 dpi on labels sized up to 4.4 x 8inches. After printing, the label is stripped from the liner andheld by suction on the tamp applicator pad. The tamp padis mounted on a heavy-duty swing arm that extends over aconveyor and tamps the label to the front surface of the carton.The device can also be set up to apply labels to a singlesurface or as a corner wrap. Tharo Systems, 800-878-6833,www.tharo.com.Optical label sensors featureintegrated teach functionalityThe LabelX sensor combines a small spot size with fastresponse for high-speed label detection. Offered in two models—theLBX-50 and LBX-100—the sensors are capable ofdetecting a variety of adhesive labels on many different typesof web backings. By differentiating between the gap and thelabel, the sensor’s fast response provides precise spatial resolutionof the label edge. An integrated Teach key makes thesensor fast and easy to use. The LBX-50 is ideal for standardand low contrast labels, while the LBX-100 model provideshigher sensitivity for nearly clear labels. EMX Industries, 800-426-9912, www.emxinc.com.62 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

Lightweight, laminated returnablepackaging curtain materialA new, lighter weight returnable packaging curtain material isoffered. The Packa-Tex 13-ounce per square yard material isa double-polished fabric that maintains the integrity of fabriccurtain and cover construction. The clear laminate is availablein 54-inch (137 cm) rolls and features a 2 x 2 scrim count. Thematerial provides a delicate, flexible method of product transportfor automotive parts, postal packages, glassware, andother fragile components or finished goods. Easily cleaned,the fabrics conformto virtually anyshape, offer easyaccess to parts, provideprotection fromhard or abrasivesurfaces, and canbe more cost effectivethan disposablepackaging. ABCIndustries, 574-267-5166, www.abc-industries.net.Servo-driven, low-level depalletizerThe Model 1000(AC)-60 low level depalletizer is a rugged,servo-driven system that provides flexibility by accommodatinga range of layer heights. The system improves accuracy inlayer incrementing with heavy loads (such as full height palletsof glass bottles) while boosting reliability by eliminatingmany of the positioning controls required with conventionalsystems. Capable of floor level depalletizing without operatorplatformsand containerlowerators, thesystem features afour-point palletlifting platform,servo-driven mainelevator, wideway pallet handling,and speedframe doorsthat give maintenance personnel better access. To betteraccommodate leaning pallets, longer layer-transfer platesand double stroke chip board grippers are also included. Forfurther machine customization, options include: perimeterguarding, right-angle pallet stackers, zoned chain or air chainpallet accumulation conveyors, servo-driven sweep drive andmultiple PLC control choices. Container Handling Systems,708-482-9900, www.containerhandlingsystems.com.SustainableDesign-Build SolutionsFINANCE SOLUTIONSTERMS UP TO 7 YEARSRATES AS LOW AS 0%LIMITED TIME OFFER. SUBJECT TO APPROVAL.fabric structuresBuildingsavailable up to300' wide.Low in cost persquare foot.Natural daytimelighting.Easy to relocate.Expandable.Little or noproperty taxes.Call one of our ClearSpan specialists at 1.866.643.1010or visit us at www.ClearSpan.com/ADMMH.mmh.com MODERN MATERIALS HANDLING / N O V E M B E R 2 0 1 2 63

Longer Lasting BeltsBetter thanLifetimeWarrantyOpen Area Corrugated Rack DeckFire Protection -Large openings (Morethan 50% open area)allow sprinkler waterthrough to lower levelsUniform Strength -High capacity withlow deflectionNo Waterfall Edge -Flush design for easylabeling on beam faceHi-Tech Look -Bright, galvanizedfinishProduct/BackFriendly -Smooth surfacereduces productdamage andpossible hangupsthat can cause injuriesScan this code for Punch Deck® Mobile!toll-free: 866-400-8107DACS inc. punchdeck.comSEE US AT PROMAT 2013 - BOOTH 2512▲U.S. Patent PendingVertical storage systemFeaturing a stabilized shelf systemwith high storage density at an affordableprice, the motorized vertical panProduct Showcasecarousel offers storage and retrieval ofinventory with push-button control. Thesystem delivers inventory to the operator,yielding retrieval time savings upEnclosed to 90%. Included hose standard reel are lifetimeprotects sealed bearings, against shielded debris motors, securityModel keypad, 5000, one-touch 7000 and 8000 forward/reverse,Thereels wire feature mesh guarding a steel enclosure and obstructionthat detectors. offers an Vidir additional Machine, level of 800-210-0141, www.vidir.protection com, Booth for the 3018. hose from potentiallyharmful foreign debris. ForaccessSoftwareto serviceabledirects,parts,analyzesthereel cover is removable on bothpaperless picking activitysides. Maximum product deliveryExecutives, managers and supervisors can easily viewis ensured with full flow shaft and• Abuse Resistant Belts work where others fail. pick rate productivity, accuracy and throughput withswivel construction, while all steelthe version 6.0 release of LP dashboard.The software displays real-• Super Strong Joints are virtually unbreakable. components are individually powder coated prior to assembly.• High Tension Belts move heavier loads.To protect the hose from wear due to angular pull, each reel’stime, updated key performance• Super Red Belts double conveyor capacity. cast guide assembly incorporates four nylon guide rollers.indicators with drill-down granularityReelcraft Industries, 800-444-3134, www.reelcraft.com.New Split Line-shaft Spoolsfor facility, area, zone and employeelevelviews. Featuring a rich graphi- High precision. Reasonable price.Software aligns inventory management Easy to install. Zero downtime.cal interface with drag-and-dropwith widgets replenishmentfor custom template views of performance Can be locked to shaft. EliminatesThe Clarity SaaS solution aligns inventory management withdata, the system offers an automatic slide-showneed for keyed spools and shafts.replenishment. The software uses precise demand forecasting,lead time forecasting, order cycle optimization, servicestyle display of multiple, user-configured templates.800-770-2358 614-777-0295 Lightning Pick Technologies, 262-250-2143, www.Dura-Belt Fax: 614-777-9448 www.durabelt.com level management, replenishment, special order considerationslightningpick.com, Booth 1543.and order validity assurance. By automatically coordinating44orders, the system supplements an enterprise resource planningsystem to help retailers, distributors and manufacturersM ARCH 2010 / MODERN MATERIALS HANDLING mmh.comcut inventory levels up to 30%, reduce lost sales by more thanMMH100301ShowProds_ID.indd 4467%, boost demand fulfillment, and achieve a 50% increase inoperating income. The system frees up a purchaser to focus ondeal opportunities, margins and vendor relations. Blue RidgeSoftware, 866-620-3917, www.blueridgeinventory.com.3/10/2010 3:49:09 PMRemote controlled shuttle for storage,retrieval of high-density palletsTo enhance storage density, the AUTOSAT shuttle pallet carrieris operated by remote control to reach heights of 492feet. It is offered in seven models and handles loads up to3,300 pounds. The machine methodically and promptly collects,stores and arranges pallet loads in their proper channels.Ideal for use in food, manufacturing, textile and pharmaceuticalindustries, the system increases storage density by morethan 20% over drive-in racking. Up to four shuttles at a timecan be controlled by a single forklift operator. Powered by alithium ion battery, the system produces no memory effect forsmoother process flow and longer operational use. To preventload overflows and collisions, the preferred distance betweenpallets can be programmed with the remote to protect loadsand racking. A below-zero package option ensures operationin cold storage to -30°F. Automatic Material Handling, 888-949-2886, www.automhausa.com.64 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

Bearing for axle-free conveyor rollersThe GenStar Eliminator 1.9-inch ABEC-1 precision bearingassembly with IronGrip adapter is offered for use withaxle-free conveyor rollers. By eliminating a thru axle atlonger lengths, the bearing’s construction enables thetube to deflect without the same axle deflection on theball races. The IronGrip steel adapter provides flexibilityfor various crimping pressures at the tube while isolatingthe ABEC-1 precision core bearing during the crimpingprocess. Inside the bore is a direct injection molded bushingmade of nylon static discharge material. Both the steeladapter and the nylon direct injected bushing provideconcentricity and extended bearing life. The dual sealedcore bearing is packed with Chevron SRI grease to accommodatea wide operating temperature range. The tubeand mated bearing assembly carry the weight of productswith reduced total roller deflection. Rollers can carry 270-pound loads and can span lengths up to 72 inches. FrantzManufacturing, 815-625-7063, www.frantz-mfg.com.EXPORT PALLET SOLUTIONSAS LOW AS US$5.00 EACHEXPORT PALLET SHORTAGE FORECASTEDTRYPRESSWOODPALLETSCLEAN, DRYMOLD FREEIPPC-ISPM 15EXPORT EXEMPTCROSS ANYBORDERCOMMITTED TO EXCELLENCE SINCE 1962LITCO INTERNATIONAL INC.855-296-2891 www.litco.comLabel HoldersErgonomic Holster SystemsclassifiedTo advertise, or for moreinformation please contact:Jennifer Drevline,847-223-5225, ext. 11,jenniferd@caseyreps.comFolding FencingLabel Holders800.242.3919www.aignerlabelholder.cominfo@aignerlabelholder.comBumpy Rides?Secure YourTerminal, andHolster YourSide Arm...with a LOGISTERRAtruck-mount Holder®Thinking aboutbuilding wallsfor security?There’s a better and lower-cost alternative:Folding Guard’s Saf-T-Fence partitions.They deliver security and an unobstructedview of your property – with no change toyour lighting or heating systems. Modularsystem can be easily installed, expandedor relocated in any space. In Stock.Download FREE guide at FoldingGuard.com/kitN E W...or a slinger,right or left• Proven products• Years in service• Deployed worldwide• Made in USAL O G I S T E R R A , I N C.619-280-9992info@logisterra.com • www.logisterra.commmh.com Modern Materials Handling / N o v e m b e r 2 0 1 2 65

modern 60 Seconds with...Ian HobkirkCommonwealthSupply ChainAdvisorsTitle: Managing directorLocation: Boston, Mass.Experience: 19 years in supply chain,including consulting and systemsintegration. Hobkirk is a former analystwith The Aberdeen Group.Primary Focus: Distribution centerdesign, network optimization, WMS selectionand implementation.Modern: What is driving endusersto upgrade their warehousemanagement systems (WMS)systems today?Hobkirk: There are really twodifferent markets. Big, establishedcompanies that already have a WMSare modernizing their systems. Thenyou have up-and-coming companiesthat don’t have anything beyond aninventory management system. Thereare different drivers in each of thosemarkets.Modern: Can you give someexamples?Hobkirk: For the establishedcompanies, one big driver is thatSAP and Oracle have come outwith significantly enhanced WMSofferings. Those releases havecoincided with a generation of CIOsthat have already been throughsystem replacements and are lesswilling to look at best-of-breedsystems. The pendulum has alwaysswung between IT and operations,and now it’s swinging toward IT. Istill wouldn’t put enterprise resourceplanning (ERP) WMS on par with best-of-breed for complex distributionenvironments, but there is a lot offunctionality there that didn’t exist afew years ago.Modern: What role is e-commerceplaying in WMS upgrades?Hobkirk: It’s playing a significantrole. Retailers are upgrading theirmaterials handling systems. Theyneed to do more complex thingslike cartonization, wave picking andcluster picking because their laborcosts to do piece picking are out ofcontrol. They need more accuratesystems. Maybe they want to managemore than one forward pick locationfor the same SKU. There are alsofactors outside of e-commerce thatare causing companies to upgradetheir WMS systems. One of those isthe need for task interleaving andtrue “task-driven warehousing.”They’re discovering that a lot oflegacy systems just can’t handle thoseprocesses. It’s not in their DNA.Modern: How about the up-andcomingcompanies that don’t reallyhave a WMS?Hobkirk: For them, it’s harder thanever to select a WMS. You’ve had alot of atrophy in the industry. Five orsix years ago, you had a few largeplayers, but you also had half adozen or so mid-tier companies withlarge user bases. The large playersare still there, but a number of thesolid mid-tier companies have beenacquired or are less visible. On onehand, the mid-tier WMS players havereally improved their features andfunctionality, but there are also morevendors that are less well-known. It’sjust harder for a user to figure outwho they should talk to. M66 N o v e m b e r 2 0 1 2 / Modern Materials Handling mmh.com

Your BEST Source for New Productsin Materials Handling!IntroducingMHPN.comYour daily sourcefor new productsCovering:• Mobile & Wireless• Lift Trucks & Accessories• Automation• Conveyors & Sortation• Containers & Totes• Packaging & Pallets• Dock Equipment• And much more!MHPN.com, Material Handling Product News’ new website, offers themost comprehensive listing of new products in the materials handlingindustry. Whether you’re looking for the newest innovations in dockequipment or the latest software to control your material flow in thewarehouse, MHPN.com is your first stop.Check out MHPN.com today!www.mhpn.com

www.cushman.comIntroducing the new Titan ® line from Cushman. ® Now available in three models (LD, HD andXD), Titan delivers a range of payload capacities up to 3,000 pounds and towing capacitiesup to 5,000 pounds, so you can find the right fit for your facility.LET’S WORK. SOME JOBS ARE TOO BIG FORONE-SIZE-FITS-ALL.© 2012 Textron Inc. All rights reserved.TITAN XDTITAN HD TITAN LD