When it comes to transporting goods, the quicker the better, right? Well, not always. All products need to be handled with care, whether you're transporting washing machines, toilet paper, or fine china. But what if your cargo is dangerous? I bet you didn't know that there are certain routes that hazardous waste and non-hazardous waste can be transported. Transportation companies are required to follow federal and state regulations that trucks containing radioactive and non-radioactive hazardous materials that specific routs are designated for transport. These routes are collected for each state and stored in a national database. A routing agency is designated by the governor and various Indian tribes responsible to coordinate and review the designated transport routes. The database includes addresses, highways, tunnels, and many landmarks that trucks are allowed to transport hazardous materials.
The other area of concern is border compliance. Hazardous materials must be properly boxed and labeled. Areas of concern are biological safety as well as chemical. Bio safety laws are vast and concern everything from potential environmental leaks to blood borne pathogens. It is vital to have policies and procedures in place to properly handle and transport these materials throughout the US.
Violation of federal and state regulations could mean fines and imprisonment for repeat offenders. There are consultants that can work with companies to maintain proper safety measures and stay within compliance.
A good way to make certain that federal and local are met is to designate a specific manager to over-see that your company follows them. It is important that adequate training is provided to everyone involved in the process and measures are in place to ensure proper protocol.
Source:
AIHA - Home
Saturday, December 27, 2008
Industrial Hygiene
I was fortunate enough to read an article by John V. Currie about industrial hygiene. He works on the basic premise that there are six steps to successfully managing hazmat safety on a work site. It is not just a matter of responding to an industrial accident but making a concerted effort to prevent illness and injury in the work place.
Currie’s six steps:
1) Develop a written policy manual, which is endorsed by management, included specific goals to achieve, and the resources to maintain the plan.
2) Establish accountability on all levels of management. He states that it is important not to overburden with so much work that he or she is not able to maintain the high standards required to maintain a healthy and safe work environment.
3) Train employees continually and consistently. Curries states that regulatory compliance should be taught consistently and suggests that several employees be trained which then become in-house trainers.
4) Allocate sufficient resources to safety compliance. Some companies do not have adequate staff so depend on outside consultants to assist them in staying within compliance. Other companies use a comprehensive computer database system, which tracks everything from inventory, transportation, to proper labeling.
5) Never become complacent about maintaining the highest standards of safety. All employees should be held accountable for their actions: even if that means reflecting poor performance standards for allowing hazardous materials to be transported without the appropriate precautions.
6) Document consistently as if you were to be audited at any time.
Currie makes many valid and important points that can be of utmost importance to maintaining a safe work environment, which ultimately could save lives and money because of workers’ compensation claims or penalties for non-compliance.
Source:
http://www.nsc.org
Currie’s six steps:
1) Develop a written policy manual, which is endorsed by management, included specific goals to achieve, and the resources to maintain the plan.
2) Establish accountability on all levels of management. He states that it is important not to overburden with so much work that he or she is not able to maintain the high standards required to maintain a healthy and safe work environment.
3) Train employees continually and consistently. Curries states that regulatory compliance should be taught consistently and suggests that several employees be trained which then become in-house trainers.
4) Allocate sufficient resources to safety compliance. Some companies do not have adequate staff so depend on outside consultants to assist them in staying within compliance. Other companies use a comprehensive computer database system, which tracks everything from inventory, transportation, to proper labeling.
5) Never become complacent about maintaining the highest standards of safety. All employees should be held accountable for their actions: even if that means reflecting poor performance standards for allowing hazardous materials to be transported without the appropriate precautions.
6) Document consistently as if you were to be audited at any time.
Currie makes many valid and important points that can be of utmost importance to maintaining a safe work environment, which ultimately could save lives and money because of workers’ compensation claims or penalties for non-compliance.
Source:
http://www.nsc.org
Chemical Warehousing
Do not make the mistake in thinking that just because you may deal in hazardous waste once in a while that you will not be responsible for everything that is involved in storing, transporting, or eliminated the hazardous waste in the proper manner. Hazmat warehousing could include the materials that are flammable or deadly gasses. It would be wise to prepare properly for the maintenance of hazardous materials or allow warehousing facilities that are properly equipped to manage the material.
Hazmat compliance requires adherence to the proper OSHA requirements, training, department of transportation DOT shipping regulations, compliance, and material safety data sheets (MSDS) displayed in proper locations, training, and reporting. The MSDS alone is an enormous data sheet that includes all the chemicals that could be located in a warehouse. Each chemical is broken down into its basic elements, the effects on the human body and environment, and the proper method of treatment in case of exposure and injury.
Warehouses that specifically deal with chemicals are required to have specific fire resistant walls, explosion proof appliances, special industrial chillers, flame and heat detectors, chemical resistant coated surfaces, special mixing rooms, and fire rated cold rooms. This is just to name a few requirements.
Non-compliance to federal and state regulations could mean heavy fines, potential injury, and illness to workers, and potential imprisonment of executive management for repeat offenses.
Sources:
hazmat safety
businessweek.com
Hazmat compliance requires adherence to the proper OSHA requirements, training, department of transportation DOT shipping regulations, compliance, and material safety data sheets (MSDS) displayed in proper locations, training, and reporting. The MSDS alone is an enormous data sheet that includes all the chemicals that could be located in a warehouse. Each chemical is broken down into its basic elements, the effects on the human body and environment, and the proper method of treatment in case of exposure and injury.
Warehouses that specifically deal with chemicals are required to have specific fire resistant walls, explosion proof appliances, special industrial chillers, flame and heat detectors, chemical resistant coated surfaces, special mixing rooms, and fire rated cold rooms. This is just to name a few requirements.
Non-compliance to federal and state regulations could mean heavy fines, potential injury, and illness to workers, and potential imprisonment of executive management for repeat offenses.
Sources:
hazmat safety
businessweek.com
Saturday, December 20, 2008
Emergency Action Plan
Per the Occupational Safety and Health Standards (OSHA), upon hire employers should provide employees with a fire prevention and safety response plan in case of an emergency. Employees must be informed of any fire hazards, and an employee emergency plan must be created and practiced to handle any reasonably expected situation.
An emergency evacuation plan should include a written evacuation plan and practice. The plan should include floor wardens that head the evacuation in case of an emergency. There should be one warden for every twenty employees. The wardens plan and practice the evacuation in case of an emergency. Each warden has a designated location to scan for employees that have not departed from the location. It is mandatory to have maps of the building and evacuation route highlighted for easy reorganization posted in highly visible locations. Have a designated location for employees to meet at a location away from the fire such as a parking lot or park near by the work site.
Emergency evacuation training should include actual emergency evacuation drills. Make sure to contact the local authorities, so that they are aware and have the option to be involved with the evacuation practice. The fire department will also work with you to evaluate the effectiveness of the current plan and give suggestions on how to improve the speed at which employees evacuate the building.
It is helpful for each floor warden to have an emergency pack and orange vests to identify him or her, so that employees recognize who to ask for instructions and assistance.
Sources:
http://www.osha.gov
An emergency evacuation plan should include a written evacuation plan and practice. The plan should include floor wardens that head the evacuation in case of an emergency. There should be one warden for every twenty employees. The wardens plan and practice the evacuation in case of an emergency. Each warden has a designated location to scan for employees that have not departed from the location. It is mandatory to have maps of the building and evacuation route highlighted for easy reorganization posted in highly visible locations. Have a designated location for employees to meet at a location away from the fire such as a parking lot or park near by the work site.
Emergency evacuation training should include actual emergency evacuation drills. Make sure to contact the local authorities, so that they are aware and have the option to be involved with the evacuation practice. The fire department will also work with you to evaluate the effectiveness of the current plan and give suggestions on how to improve the speed at which employees evacuate the building.
It is helpful for each floor warden to have an emergency pack and orange vests to identify him or her, so that employees recognize who to ask for instructions and assistance.
Sources:
http://www.osha.gov
Warehouse OSHA Compliance
Federal regulations require companies in the U.S. to meet Occupational Safety and Health Standards (OSHA) in an effort to reduce or eradicate work related injuries or illness. Organizations are required to provide a formal written safety plan if they have ten employees or more. An oral safety plan is acceptable for companies that have fewer than ten employees. The written plan must cover preventative measures and disaster recovery steps, which list the actions that are required in case of an emergency.
Safety training must be provided for each potential hazard that may occur in your warehouse.
For example:
The training for a forklift / pallet jack operators must address safety areas such as avoidance of collisions by the use of signs, horns, and proper lighting and driving. Operators should be trained on how to conduct a proper inspection and hazard recovery.
A janitorial service should cover topics such as chemicals used and repercussions and first aid in case of chemical exposure.
Another area of importance is instruction on what to do in case of exposure to a chemical hazard and where the first aid equipment is kept.
Safety training should include a combination of classroom and hands-on demonstration. Employee training should be ongoing and revised to keep up with changing industry and OSHA standards. Non-compliance could mean hefty fines that could ranges from $7,000 per incident to $70,000 for willful repeat violations.
Sources:
OSHA Compliant Safety Programs & Training
http://www.osha.gov
Safety training must be provided for each potential hazard that may occur in your warehouse.
For example:
The training for a forklift / pallet jack operators must address safety areas such as avoidance of collisions by the use of signs, horns, and proper lighting and driving. Operators should be trained on how to conduct a proper inspection and hazard recovery.
A janitorial service should cover topics such as chemicals used and repercussions and first aid in case of chemical exposure.
Another area of importance is instruction on what to do in case of exposure to a chemical hazard and where the first aid equipment is kept.
Safety training should include a combination of classroom and hands-on demonstration. Employee training should be ongoing and revised to keep up with changing industry and OSHA standards. Non-compliance could mean hefty fines that could ranges from $7,000 per incident to $70,000 for willful repeat violations.
Sources:
OSHA Compliant Safety Programs & Training
http://www.osha.gov
Warehouse Security
Unfortunately, thousands of dollars worth of inventory is lost or stolen because of theft from either outside sources or employees. Companies have experienced loss because of vandalism, theft, or hazards. The benefit of a security system is the peace of mind gained because of constant monitoring of the warehouse and its inventory. The use of security systems is more cost effective than many believe it to be, and loss can be prevented or mitigated by taking advantage of a variety of options.
Several Methods of Security
A good method of monitoring inventory loss is through the use of an inventory management system that utilizes an internal software system that integrates a myriad of scanning and voice controlled tracking methods, which employs part numbers or SKUs.
Close circuit television is another method that will allow you to monitor individuals and activities that are in the warehouse. Supervisors and managers have the capability of monitoring several areas from a remote location. This option can allow you to capture and archive the information for future reference. There is a wide scope of video conferencing systems to accommodate a wide variety of needs and price range.
Do your homework when researching a security system. A good company will provide you a consultant that works with you to create a system that are suitable and cost efficient to meet your needs. Make sure the security company is licensed, has a good reputation, and to get three or four quotes from different vendors.
Sources:
Security Systems
http://www.buyerzone.com/security
Several Methods of Security
A good method of monitoring inventory loss is through the use of an inventory management system that utilizes an internal software system that integrates a myriad of scanning and voice controlled tracking methods, which employs part numbers or SKUs.
Close circuit television is another method that will allow you to monitor individuals and activities that are in the warehouse. Supervisors and managers have the capability of monitoring several areas from a remote location. This option can allow you to capture and archive the information for future reference. There is a wide scope of video conferencing systems to accommodate a wide variety of needs and price range.
Do your homework when researching a security system. A good company will provide you a consultant that works with you to create a system that are suitable and cost efficient to meet your needs. Make sure the security company is licensed, has a good reputation, and to get three or four quotes from different vendors.
Sources:
Security Systems
http://www.buyerzone.com/security
Saturday, December 13, 2008
Belt Conveyor Systems
Conveyor systems come in many configurations and sizes. Along with sorter systems and overhead systems, there are belt conveyor systems.
Conveyor systems form the core of the distribution center. Cartons travel from multiple conveyors and are then merged in the next level of packaging. Conveyors carry cartons to meter belts, which place the packages equidistantly. They are weighed, labeled, and the UPC codes are compared for accuracy. The cartons then travel into appropriate locations for palletization and shipping.
The gravity roller is a non-powered system that can be built for temporary or permanent uses. They are good for moving uneven or open packages.
The low profile conveyor system is versatile and used for packaging, sorting, small parts transfer, and streamlining.
The skatewheel conveyor is a workhorse. It is a heavy- duty conveyor used for shipping, and assembly. It is best for smooth flat bottom items and is used for dip configuration, lid extractors, and customer pushing.
Shoe sortation sorts at 75 to 200 cartons per minute. It is useful for moving a variety of products and packages that are varying sizes and shapes. It is exceptionally good for delicate items, because it moves smoothly.
The vertical conveyor speaks for itself. It fits almost anywhere because, it moves up and down rather than horizontally. It is typically in a spiral configuration, saves space, and moves the items through a controlled decent.
Companies like Bastian Solutions offer consulting services as part of the purchasing experience, so take advantage of the expertise of professionals to help you determine your needs.
Sources:
bastiansolutions.com
Modern Materials Handling
Conveyor systems form the core of the distribution center. Cartons travel from multiple conveyors and are then merged in the next level of packaging. Conveyors carry cartons to meter belts, which place the packages equidistantly. They are weighed, labeled, and the UPC codes are compared for accuracy. The cartons then travel into appropriate locations for palletization and shipping.
The gravity roller is a non-powered system that can be built for temporary or permanent uses. They are good for moving uneven or open packages.
The low profile conveyor system is versatile and used for packaging, sorting, small parts transfer, and streamlining.
The skatewheel conveyor is a workhorse. It is a heavy- duty conveyor used for shipping, and assembly. It is best for smooth flat bottom items and is used for dip configuration, lid extractors, and customer pushing.
Shoe sortation sorts at 75 to 200 cartons per minute. It is useful for moving a variety of products and packages that are varying sizes and shapes. It is exceptionally good for delicate items, because it moves smoothly.
The vertical conveyor speaks for itself. It fits almost anywhere because, it moves up and down rather than horizontally. It is typically in a spiral configuration, saves space, and moves the items through a controlled decent.
Companies like Bastian Solutions offer consulting services as part of the purchasing experience, so take advantage of the expertise of professionals to help you determine your needs.
Sources:
bastiansolutions.com
Modern Materials Handling
Warehouse Overhead Conveyor Systems
Sorters are used in many industries including general merchandise, apparel, specialty, catalog, retail, wholesale, and parcel post including envelopes. Merchandise picking and sorting systems help to decreases errors and increases productivity by providing a fast, consistent form of transportation that can be modified to suit the needs of the warehouse facility. Part of the sortation system in manufacturing and distribution plants is the overhead conveyer system.
The overhead conveyor is a motorized suspended system that is either a bi-rail or a single rail transportation system typically for lighter loads.
The automated electrified system is used for long distances, sorting, buffering, and distribution. It is versatile, fast, can incline and decline, and has the capability of moving to a 90-degree angle.
The enclosed tracer is most economical. It is used for moving parts, dipping, assembly, and mobile storage. It is useful for moving product between buildings and long distance.
The overhead chain conveyor can conform to the structural contours of the building. It can easily be modified to add workstations, relocate the conveyor, or revise the path to accommodate business needs.
Overhead conveyor systems are an excellent alternative in tight spaces. They are an effective yet innovative way to streamline your warehouse practice.
Sources:
World Intellectual Property Organization
Overhead and Ceiling Hung Conveyor Systems
The overhead conveyor is a motorized suspended system that is either a bi-rail or a single rail transportation system typically for lighter loads.
The automated electrified system is used for long distances, sorting, buffering, and distribution. It is versatile, fast, can incline and decline, and has the capability of moving to a 90-degree angle.
The enclosed tracer is most economical. It is used for moving parts, dipping, assembly, and mobile storage. It is useful for moving product between buildings and long distance.
The overhead chain conveyor can conform to the structural contours of the building. It can easily be modified to add workstations, relocate the conveyor, or revise the path to accommodate business needs.
Overhead conveyor systems are an excellent alternative in tight spaces. They are an effective yet innovative way to streamline your warehouse practice.
Sources:
World Intellectual Property Organization
Overhead and Ceiling Hung Conveyor Systems
Warehouse Sortation Systems
So easily overlooked, yet such an integral part of the warehousing business is the distribution sortation systems. Having the right sortation system conveys improved cost and customer service by increasing efficiency. Take into consideration the automation of order picking integrated with material handling via a conveyor system. Commodities are categorized by conveyable and non-conveyable. Conveyable goods move along the distribution center at various speeds depending upon the product and processing requirements. The packages move at a high volume to their destination, to truck docks, and routs.
Sortation Techniques
Low rate sortation typically moves items at about 15 to 20 items per minute and includes the use of a diverter arm that comes across the conveyer to divert the produce onto another conveyor. It can be either manual or automatic. Included in this category is the right angel transfer sorter, which moves the product onto another conveyor at a 90-degree angle.
The medium speed sorter moves approximately 30 to 100 items per minute and typically includes sorters like pop-up wheel sorters for smaller, uniform packages, or multi-belt sorters for sorts at 30 degrees or 90 degrees.
High-speed sortation is available in a variety of configurations. The carousel is used to sort products that are a variety of sizes, and SKUs to be sorted to various locations. A high-speed sorter can accommodate up to 500 SKUs.
There are sorters than can move product at 10,000 items per minute. Sortation systems play a fundamental roll in the distribution industry, so it is imperative to work with a consultant in the field to choose the appropriate system for your warehouse.
Sources:
Diamond Pheonix
bnet.com
Sortation Techniques
Low rate sortation typically moves items at about 15 to 20 items per minute and includes the use of a diverter arm that comes across the conveyer to divert the produce onto another conveyor. It can be either manual or automatic. Included in this category is the right angel transfer sorter, which moves the product onto another conveyor at a 90-degree angle.
The medium speed sorter moves approximately 30 to 100 items per minute and typically includes sorters like pop-up wheel sorters for smaller, uniform packages, or multi-belt sorters for sorts at 30 degrees or 90 degrees.
High-speed sortation is available in a variety of configurations. The carousel is used to sort products that are a variety of sizes, and SKUs to be sorted to various locations. A high-speed sorter can accommodate up to 500 SKUs.
There are sorters than can move product at 10,000 items per minute. Sortation systems play a fundamental roll in the distribution industry, so it is imperative to work with a consultant in the field to choose the appropriate system for your warehouse.
Sources:
Diamond Pheonix
bnet.com
Saturday, December 6, 2008
Investing In Warehouse Technology
There is so much to an automated storage and retrieval system that a blog can only scratch the surface of a topic, so I strive to give you basic knowledge about a topic but endeavor to try to inform as much as possible effectively but as concise as possible. In this spirit, I will write about the benefits of an automated system, which lowers labor costs, order time and increases pick and pack accuracy.
New technology allows warehouse facilities to take advantage of the huge strides in warehouse distribution methods in the endeavor to reduce costs and improve accuracy. Warehouse distribution centers have turned to the automation of many of the practices. Part of the goal of automation is to increase accuracy of put away and replenishment as well as many other functions to an astounding 99% accuracy rate. How? By investing in new technology.
For instance, pick to light and voice is the use of voice directed order picking, sortation, retrieval, picking, sorting, and retrieval process. The goal is to work fast and efficiently, by reducing error and as well as reduce labor costs while increasing return on investment.
An automated system is not cheap but there are studies to demonstrate that the implementation of the right system will reduce costs over the long term while increasing productivity. Research the options thoroughly and work with a consultant to make sure that the system you invest in is right for your business.
Source:
Automation drives warehouse profits
New technology allows warehouse facilities to take advantage of the huge strides in warehouse distribution methods in the endeavor to reduce costs and improve accuracy. Warehouse distribution centers have turned to the automation of many of the practices. Part of the goal of automation is to increase accuracy of put away and replenishment as well as many other functions to an astounding 99% accuracy rate. How? By investing in new technology.
For instance, pick to light and voice is the use of voice directed order picking, sortation, retrieval, picking, sorting, and retrieval process. The goal is to work fast and efficiently, by reducing error and as well as reduce labor costs while increasing return on investment.
An automated system is not cheap but there are studies to demonstrate that the implementation of the right system will reduce costs over the long term while increasing productivity. Research the options thoroughly and work with a consultant to make sure that the system you invest in is right for your business.
Source:
Automation drives warehouse profits
Automated Guided Vehicles - AGV
A concern for many warehouse facilities is saving costs, in part because of labor cost, and workers ’ compensation claims due to injuries. The two are indelibly intertwined. Although warehouse companies take appropriate measures such as safety training, safety gear, and reward systems for low or no injuries. Inevitably, someone will file a claim because of taking a wrong step, bumping into something, or worse. Automated guided vehicles have become an integral part of a large manufacturing and distribution plants. Both by providing a safe and efficient method of transport and picking and packing but also lowering labor costs and fewer workers’ compensation costs.
Fewer workers mean fewer incidents of accidents and reduced labor and material costs. However, what does this entail? Not just a forklift, but also a major integrated system. Robotic cars that have a pre-defined path using either of three methods that follow a path throughout the distribution center. The robotic carts follow these paths using buried inductive wires, surface mounted magnetic or optical stripes, or laser guidance. These vehicles are highly sophisticated integrated systems that allow large operations to perform the same duties as forklift operators, which do pick up and deliver of pallet loads.
Another benefit is that it allows large operations to perform at high capacity through 24-hour shift operations. It is possible for distribution centers to use hundreds of these vehicles at a time. They can be coordinated on the floor to provide instant reporting to track stock and interface with the order department as well at the integration with robotic palletizers and wrappers.
This new technology has become a boon in the industry as a major roll for warehouses to work efficiently and effectively.
Sources:
http://www.highbeam.com/doc/1G1-16137369.html
Fewer workers mean fewer incidents of accidents and reduced labor and material costs. However, what does this entail? Not just a forklift, but also a major integrated system. Robotic cars that have a pre-defined path using either of three methods that follow a path throughout the distribution center. The robotic carts follow these paths using buried inductive wires, surface mounted magnetic or optical stripes, or laser guidance. These vehicles are highly sophisticated integrated systems that allow large operations to perform the same duties as forklift operators, which do pick up and deliver of pallet loads.
Another benefit is that it allows large operations to perform at high capacity through 24-hour shift operations. It is possible for distribution centers to use hundreds of these vehicles at a time. They can be coordinated on the floor to provide instant reporting to track stock and interface with the order department as well at the integration with robotic palletizers and wrappers.
This new technology has become a boon in the industry as a major roll for warehouses to work efficiently and effectively.
Sources:
http://www.highbeam.com/doc/1G1-16137369.html
Choosing a Warehouse Forklift
The selection of forklifts for warehouse facilities is phenomenal, so when you need one which do you need? Warehouses move thousands of products a day that range in size and weight from several thousand pounds to light items that require assembly. Warehouse facilities utilize automated guided vehicle systems (AGVS) that range from simple manual controlled vehicles like forklifts to sophisticated computer integrated systems.
One type of automated vehicle is the forklifts. There are several determining factors to consider when choosing a forklift.
Will it be for indoor or outdoor use and the type of combustion process are you interested in using. For instance, are you interested in going the “green” route by purchasing an electric forklift that is clean burning and typically quieter. The other option is a gas or diesel burning vehicle, which is less expensive.
Another consideration is the type of product that you will be moving. Weight and height requirements are very important. Will the product weight several hundred or several thousand pounds? Will the item or pallet be five feet or twenty feet tall? Center of gravity will also be a determining factor, which will affect the load capacity of the vehicle.
Think about the aisle space you have and maneuverability that will be required by the vehicle. A stock picker is designed for both pallet handling and picking product at tall heights. A rider pallet truck and tow truck is for low-level order picking, high-speed transport, or dock work. A turret truck is used for very narrow aisle and is designed for pallet handling and case picking.
First step first: Determine what is the main purpose or job for which the forklift is needed?
Source:
Forklift Comparisons
MHIA.org Automatic Guided Vehicle Systems
One type of automated vehicle is the forklifts. There are several determining factors to consider when choosing a forklift.
Will it be for indoor or outdoor use and the type of combustion process are you interested in using. For instance, are you interested in going the “green” route by purchasing an electric forklift that is clean burning and typically quieter. The other option is a gas or diesel burning vehicle, which is less expensive.
Another consideration is the type of product that you will be moving. Weight and height requirements are very important. Will the product weight several hundred or several thousand pounds? Will the item or pallet be five feet or twenty feet tall? Center of gravity will also be a determining factor, which will affect the load capacity of the vehicle.
Think about the aisle space you have and maneuverability that will be required by the vehicle. A stock picker is designed for both pallet handling and picking product at tall heights. A rider pallet truck and tow truck is for low-level order picking, high-speed transport, or dock work. A turret truck is used for very narrow aisle and is designed for pallet handling and case picking.
First step first: Determine what is the main purpose or job for which the forklift is needed?
Source:
Forklift Comparisons
MHIA.org Automatic Guided Vehicle Systems
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