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Efficient storage and handling – the fast track to lower costs and high productivity
Hard-pressed manufacturing and assembly firms are understandably focusing attention on their core activities to manage costs, improve performance and stay competitive. However Keith Couzens of Couzens Storage Solutions is convinced that taking a hard look at the often neglected area of storage and handling could provide many in the industry with almost immediate cost savings, improved productivity – and a safer working environment
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nlike warehousing and distrib- ution companies where effi- cient storage and handling operations are crucial to busi- ness success, or even survival, manu- facturing and assembly companies have traditionally concentrated on aspects such as engineering, research and production technologies rather than storage. Conversely, the function responsible for holding and supplying raw materials and components, work- in-progress, tools and jigs to the manu- facturing or assembly process is often neglected and not seen as an integral part of the business process. In more than 20 years visiting facto- ries and engineering businesses, the adverse effects of inadequate storage have been only too evident with raw materials on the floor or up against the wall with overhead space unused, boxes and pallets with no clear organi- sation or discipline, little or no secu- rity and too much stock of the wrong materials. The end result continues to be production delays, quality issues, labour-intensive storage and handling, and sadly unsafe and potentially dangerous handling practices. While the distribution sector stores mainly uniform, standardised items such as parcels, boxes and palletised goods that readily lend themselves to efficient storage and handling, produc- tion facilities routinely need to cope with a variety of shapes, sizes, weights and awkward items. They can range from metal stock items weighing several tons, through jigs and tools, to small, high value electronic compo- nents, requiring a complex or bespoke solution.
But the rewards can be immense. Manufacturer of luxury motor yachts Sunseeker purchased an integrated carousel-based picking and storage system from Couzens Storage Solutions, which enabled it to reduce
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stock levels by 25 per cent at the same time as production rose by 50 per cent. Aluminium profile building systems company SAPA is using two Modula storage systems from Couzens Storage Solutions to store an estimated 153,000 items in 1,258 lines including fixings, seals, handles, brackets and other components for its Gloucester- based replacement window and con- servatory business. They are being used to hold small and medium parts to support production, providing nearly 400m2 of storage space on a footprint of only 28.5m2, and a total combined capacity of over 120,000kg. Such systems are in growing demand as they are able to reduce nec- essary floor space by up to 80 per cent, improve pick rates to make timely, accurate deliveries to the production line, provide efficient and sophisti- cated stock management systems inte- grated with established manufacturing software. They enable companies to make far more productive use of labour and provide a safe and secure working environment. When any item is called up by the operative, typically using a PC screen for instructions, it is presented in seconds at a comfortable working height for immediate picking and dispatch to wherever it is needed. TowerMat is an outstanding exam- ple of the kind of compact storage and picking systems conceived to meet the diverse demands of the engineering and manufacturing environment. A Vertical Lift system designed for the heaviest, toughest and ugliest of stor- age tasks, including metal sheet, bar, profiles, jigs, machine tools and heavy, bulky components, TowerMat is able to bring an exceptionally wide range of materials together in a single, space- saving and secure unit. Each storage cassette can hold up to 5,000kg with dimensions up to 10m long x 2.0m wide. Units are available up to 18m
Above: TowerMat solution for German construction crane manufacturer GEDA while SAPA Building System (top left) uses two Modula storage systems
high and with modular design, there is no practical weight limit.
Goods are presented for handling via a powered cart, able to exit the TowerMat unit from the front, rear or sides or all faces, for delivering to a workstation or any other location away from the machine. Alternatively the load can be taken away by forklift, overhead crane or other automated handling machinery, avoiding the need for manual handling and prac- tices that would not meet today’s health and safety standards. German building products manufac- turer GEDA is using a TowerMat linked directly to a Trumpf laser cut- ting machine handling sheet metal stock in cassettes up to 9.8m wide, illustrating how machines can be inte- grated as part of a total processing and manufacturing system.
More efficient modern storage sys- tems such as vertical lifts and carousels have the potential to achieve such significant improvements that the payback period can be very short, while the benefits in terms of improved productivity, lower stock levels and more productive use of labour will endure for years to come.
Couzens Storage Solutions T: 01442 250010
www.verticalcarousel.co.uk Enter 302
NOVEMBER/DECEMBER 2011 Factory Equipment
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