When it comes to forklift safety, good operator training will always be Number One. But a variety of lift truck accessories, devices, and technology products can also help you enhance safety for forklift operators and pedestrians in your warehouse. Here are some recent examples that are now on the market.
FORKLIFT ANTI-COLLISION SYSTEM
ELOshield, a forklift anti-collision system, made its U.S. debut at the Modex 2018 show in Atlanta. ELOshield was developed by Elokon, a European provider of lift truck safety technology.
ELOshield is a UHF (ultra-high-frequency)-based warning system that helps prevent industrial truck accidents (both vehicle-to-vehicle and vehicle-to-person). A fixed-site version monitors accident-prone areas, such as high-traffic aisle intersections. A mobile version monitors zones of up to 50 feet around moving vehicles. These zones can be programmed, by vehicle, as circles, symmetrical rectangles, or asymmetrical polygons. Two zones, representing "warning" and "danger" risks, can trigger different system reactions.
When trucks get too close to each other or pedestrians, the truck-mounted display sends an audible and/or visual alert, automatically slows the truck down to "creep speed," and, if desired, stops the truck. If pedestrians come too close to a truck, their tags vibrate and sound an alarm.
This advanced driver-assistance system includes ID tags for industrial trucks, pedestrians, and fixed locations (like racking or doorways), as well as operator displays for each vehicle and a charging system for the pedestrian tags. (Elokon, www.elokon.com)
FORKLIFT SAFETY STROBE LIGHTS
TVH in the Americas (TVH), a supplier of replacement parts for material handling and industrial equipment, has added new dual-color strobes to its ML2 LED, ML5 LED, and ML55 LED series forklift safety lights. These strobes come in four different color combinations: amber/blue, amber/clear, amber/red, and blue/red. The dual-color option is ideal for alerting other workers of a forklift's action, the company says. If the forklift is moving, the strobe will flash one color. When the forklift is stopped and the forks are lifting, the strobe will flash the other color, indicating that the forklift is in use and not just parked.
Each strobe series is rated 12-80VDC. All of the units have six LEDs per head (three of each color) and come with a two-year warranty. (TVH in the Americas, www.tvh.com)
STANDUP FORKLIFT UNDERRIDE PREVENTION
The Backbone from Lakeport Metalcraft Inc. is a vertical metal bar designed to prevent serious and potentially fatal injuries to operators of reach trucks and standup forklifts caused by horizontal objects intruding into the operator's compartment. According to the device's manufacturer, most of these accidents occur during rearward collisions with racking—for example, when a horizontal rack beam penetrates the operator compartment.
The Backbone is easy to install and attaches in minutes, according to the manufacturer. It also complies with the ANSI B56.1 safety standard for lift trucks and meets the requirement to withstand the impact of a fully loaded truck traveling 1.6 km/h, or approximately 1 mph. (Lakeport Metalcraft Inc., www.lakeportmetalcraft.com)
DOCK SAFETY COMMUNICATION SYSTEM
When used in concert with its Dok-Lok vehicle restraint system, Rite-Hite's Corner-Vu, Leveler-Vu, Pedestrian-Vu, and new Approach-Vu warning systems make forklift operators and pedestrians aware of lift truck activity in and around loading and receiving docks as well as inside truck trailers, improving safety for everyone.
Corner-Vu lights (see photo) are located on the upper corners of the interior dock door, without obstructing the forklift driver's view. A green light means the trailer is safely secured to the loading dock with a Dok-Lok restraint, while a red light indicates the trailer is not secured and is unsafe to enter. Corner-Vu lights also serve as a reference point for the overhead door opening.
Leveler-Vu helps prevent accidents by conveying Dok-Lok status to the forklift operator while he or she is inside the trailer. A green light means the trailer is safely secured to the loading dock with a Dok-Lok restraint. A red light indicates the trailer is not secured. The lights also serve as a reference point of the leveler location for the lift truck operator when backing out of the trailer. Leveler-Vu lights mount into the back of the leveler in the standard weather-seal channel and are positioned below the surface of the leveler, preventing direct contact with forklifts.
Pedestrian-Vu communicates to pedestrians and material handling equipment operators on the dock that there is activity inside a trailer. Motion sensors are located on each side of the dock door and are aimed inside the trailer; an intense flashing blue light is emitted onto the dock leveler when motion is detected inside the trailer. Pedestrian-Vu also works in conjunction with Dok-Lok to alert any dockworker or forklift that enters an unsecured trailer. The blue light flickers as an audible alarm alerts the worker that he or she has entered an unsecured trailer, while the external light system simultaneously changes to red, warning the truck driver that there is activity inside the trailer.
Outside the dock opening, from a fixed location above the dock door, the Approach-Vu sensor detects the motion of a tractor-trailer backing into a dock position. A visual and audible alarm located on the Dok-Lok vehicle restraint alerts dock workers and pedestrians of the impending danger. According to the manufacturer, this multisensory alert system is important because ambient noise often masks the sound of a cab's engine, which can be 70 feet or more from the back of the trailer. (Rite-Hite, www.rite-hite.com)
LED FORKLIFT WARNING LIGHT
Industrial lighting expert Larson Electronics LLC has released the EXHL-TRN-RPS-LE4-FKWL-BLU-M, a new 25-watt rechargeable blue LED forklift warning light. The unit produces 2,250 lumens of intense blue light that is visible both during the day and at night to indicate the forklift's pathway, warning pedestrians of ongoing forklift operation.
The explosion-proof light operates on a rechargeable lithium-ion battery with eight hours of runtime. An unbreakable polycarbonate lens covers the light. The unit's housing, constructed of extruded aluminum, is waterproof to three meters and is resistant to dust, dirt, and humidity. The light can operate in temperatures of minus 40 degrees C to 60 degrees C (minus 40 degrees F to 140 degrees F), and is resistant to shock and vibration. An adjustable magnetic mount allows operators to control the tilt and rotation of the LED. (Larson Electronics LLC, www.larsonelectronics.com)
ARC SAFETY LIGHT
According to Panacea Aftermarket Co., its exclusive patent-pending LED forklift arc safety light is the world's first. When used in conjunction with the company's red zone forklift safety lights, the light provides 75 times the coverage of standard blue forklift lights, the company says.
The safety light projects a wide, brightly colored line around the front, back, and sides of the truck, with forward and rear projection of eight to 12 feet. It is available in 12 to 80 volts and three colors: red, blue, and green. With an IP67-rated aluminum housing, the arc light comes with a lifetime warranty. (Panacea Aftermarket Co., panaceaco.com)
FORKLIFT SAFETY AND LOAD PROTECTION PRODUCTS
Australia-based SumoSafe Global says it offers a range of "ingeniously simple yet highly innovative" products that significantly reduce damage to palletized loads, making forklift trucks safer to operate.
The SumoSafe lineup includes:
SumoSafeforks—a radical new design of lift truck fork that takes traditional steel tines and encases the tips within a protective glove. Made from industrial-grade polyurethane, the glove limits the impact of a carelessly driven lift truck's forks against a load.
SumoGloves—a variation on the SumoSafefork. SumoGloves are quickly and easily fitted to the tips of a lift truck's existing forks. They are compatible with all common makes and sizes of forklift tines.
SumoVision—a system that improves an operator's forward visibility even when sightlines are obscured by a large bulky load.
SumoLevel—a new forklift mast-tilt indicator system that reduces accidental damage to pallets, loads, and racking caused by a lift truck's forks during pallet picking and putaway.
SumoBackbone—a protective device that can be retrofitted to any lift truck make or model to minimize the risk of an operator's suffering a spine or whiplash injury from reversing into a stationary object or being hit from the rear by another forklift. (SumoSafe Global, www.sumosafe.net)
COLLISION ALERT SYSTEM
Sensor solutions provider Sick's backup assistance system (BAS) is a stand-alone aftermarket solution that actively alerts the operator to unseen obstructions behind the forklift, which contributes to a reduction in accidents.
Using the manufacturer's compact, advanced laser measurement scanner, the backup assistance system gives real-time feedback to the driver via an audible warning only when the truck is too close to any stationary or moving object. This intelligent system, which was designed specifically for forklifts, can be connected to the reverse-drive function of the vehicle to eliminate false alarms. Kits are available for different-voltage trucks and electrical systems, the company says. (Sick Inc., www.sickusa.com)
SAFETY-DATA COLLECTION BELT
Modjoul Inc.'s SmartBelt improves safety by tracking forklift drivers' actions and identifying risky behaviors that could lead to safety incidents. The wearable SmartBelt uses sensors and a geographic positioning system (GPS) to gather data about location, motion, and environment, giving companies information that can help them understand behaviors and activities that lead to injuries, the manufacturer says.
Data are collected based on counts, duration, and rate of the employee's activities, including walking, sitting, falling, driving, bending, and tripping. The SmartBelt transmits the data to the cloud via Wi-Fi, and the information is reported in three customizable dashboard views: CEO, Supervisor, and Employee. The dashboard reports allow the viewer to see an overview and ranking of an employee's safety as well as to look at specific events and track an employee's location. The software allows the owner to go back in time to review the data leading up to and following an incident.
Available in sizes from 30 to 44 inches, the SmartBelt uses vibrations to send alerts from a supervisor to the wearer. If the wearer encounters a problem, an alert button located on the bottom of the SmartBelt buckle can be used to notify a supervisor via Wi-Fi and the Modjoul mobile app. The SmartBelt has a battery life of up to 12 hours; charging at the end of every shift is recommended. (Modjoul Inc., www.modjoul.com)
Robotic technology has been sweeping through warehouses nationwide as companies seek to automate repetitive tasks in a bid to speed operations and free up human labor for other activities. Many of those implementations have been focused on picking tasks, a trend driven largely by the need to fill accelerating e-commerce orders. But as the robotic-picking market matures and e-commerce growth levels off, the robotic revolution is shifting behind the picking lines, with many companies investing in pallet-handling robots as a way to keep efficiency gains coming.
“Earlier in this decade and the previous decade, we [saw] a lot of [material handling] transformation around e-commerce and the handling of goods to order,” explains Josh Kivenko, chief marketing officer and senior vice president at Vecna Robotics, which provides autonomous mobile robots (AMRs) for pallet handling and logistics operations. “Now we’re talking about pallets—moving material in bulk behind that line.”
Kivenko explains that whether items are being packaged and shipped directly to a customer’s home address or moved as finished goods to a shipping bay for store delivery, those items are first moved in bulk in some way, often by human hands and with human-operated equipment. He describes warehouses as chaotic environments in which humans move pallets and cartons in multiple ways—up and down, side to side, from receiving to storage, from storage to shipping, or via cross-docking. Automation can help bring order to that chaos.
“What we’re trying to do is relieve some of the pressure [on the] humans [doing] this work,” Kivenko says of companies that develop pallet-handling robotic technologies. “At the end of the day, we’re trying to automate some of those flows, relieve labor pressure, save costs, and keep the goods flowing.”
But automated pallet handling isn’t right for every situation, so it’s important to understand the warehouse conditions required and the protocols and best practices needed to make it a win. Here are some guidelines for applying pallet-handling robots and gaining the most from your investment.
FIRST, UNDERSTAND THE TECHNOLOGY
Pallet-handling robots fall into four general categories, explains Rich O’Connor, vice president of storage and automation for Raymond West Group, a business unit of lift truck manufacturer The Raymond Corp. They include:
Palletizing/depalletizing robots, which are used to load or unload items onto and off of pallets, usually with the use of a robotic arm for picking and placing. Today, these systems are being increasingly integrated with automated storage and retrieval systems (AS/RS) to further streamline pallet handling in the warehouse, O’Connor explains.
Autonomous guided vehicles (AGVs) and autonomous mobile robots (AMRs), which are used to transport pallets within the warehouse. Often outfitted with lift decks or conveyors, or designed to tug or tow items, these robots move pallets from point A to B within a facility. AGVs, which often follow a marked guide-path or wire in the floor, have been around for many years, but the advent of high-performance guidance and vision systems is allowing them more flexibility today, O’Connor says. AMRs are self-guided vehicles that use software and sensors to navigate their way through the warehouse.
Forklift AGVs and AMRs, which can move products both horizontally, from place to place, and vertically, into and out of storage racks. They come in various styles—including stackers, counterbalanced trucks, reach trucks, and even very narrow aisle (VNA) vehicles for use in densely packed warehouses. These vehicles are more complex than those used only for horizontal transport, O’Connor explains. They must be “highly integrated” into the facility’s warehouse management system (WMS) or warehouse execution system (WES) so that they know precisely where to retrieve and deliver pallets within the facility.
Robotic pallet shuttles, which move pallets into, out of, and within dense storage racking. The Raymond Corp. describes such a system as “a standalone, automated deep-lane pallet storage system that utilizes self-powered shuttle carriages to move pallets toward the back or front in a racking channel. Shuttles are motor driven and travel along rails within a storage lane.”
O’Connor and others say that no matter which of these technologies you’re investing in, it’s important to remember that they are all part of a larger system designed to optimize operations throughout the warehouse.
“The expanding role of all these different styles working together is what’s amazing today,” O’Connor says.
SECOND, ENSURE THE TECHNOLOGY IS A FIT
Kivenko, of Vecna, also emphasizes the importance of pallet-handling robots working in concert, particularly AMRs and AGVs.
“The magic isn’t just that the robots are autonomous and driving by themselves. The magic is multiple robots—when you have a [whole integrated] system [in place],” he says. “[It’s] how the fleet operates autonomously and optimizes itself for continuous improvement. That’s where the exponential gains are. [It’s] not just about automating what a worker does; it’s about automating a system.”
But you can’t install these systems in just any warehouse and expect magic. Kivenko and others point to certain conditions that enable the best robotic pallet-handling outcomes, especially when it comes to transportation-based and forklift-type AMRs and AGVs.
“The robots that I sell are large-load machines with very expensive technology,” Kivenko explains. “They move material, generally, in larger facilities. And in order for them to produce a return [on investment]—because that’s the name of the game here—they have to be higher-velocity facilities.”
He says pallet-handling robots work best in large facilities running multiple shifts, usually more than five days a week. Wider aisles allow the equipment to move more freely through the facility and at higher speeds, to optimize efficiency and productivity. Strong Wi-Fi networks and clean, dry environments also help keep equipment running at top performance.
O’Connor agrees that pallet-handling robots are best suited to facilities with multishift operations, where they can ease labor constraints and boost productivity. And he says many customers are willing to extend the typical two- to three-year ROI period to five years in order to achieve those gains. But there is even more to it than that. O’Connor’s colleague John Rosenberger says customers must first step back and analyze their processes to ensure that, even if they have the right facility for pallet-handling AMRs or AGVs, they are moving material in the most efficient way to begin with.
“Many times, we find that the processes in place [are inefficient],” says Rosenberger, who is director of iWarehouse Gateway and global telematics for The Raymond Corp. He emphasizes the importance of analyzing existing data—from an equipment telematics system or similar—to determine the best path toward automation.
“Do you have congestion zones now?” he asks. “They’ll still exist if you automate [those processes exactly].”
THIRD, MAKE SIMPLICITY A PRIORITY
Another basic rule of thumb when implementing pallet-handling robotics: Keep it simple.
Andy Lockhart, director of strategic engagement for global warehouse and logistics process automation company Vanderlande, says that when designing a pallet-handling robotics system, “you want to minimize the processes you [automate]. When you can create [an automated system] that focuses on one task—for example, AMRs delivering pallets from a high-bay [storage rack] directly to the palletizing cell—you can do that efficiently and effectively. When you ask the AMR to do this and this and this … you are adding risk of failure.”
Lockhart’s colleague Jake Heldenberg advises customers to first test their target processes via pilot programs within the warehouse or DC. Heldenberg is Vanderlande’s head of solution design, warehousing, North America.
“If AGVs or AMRs for pallet handling are interesting [to a customer], the best thing to do is pilot one or two in an existing DC,” he says, explaining that the process can help companies troubleshoot, understand integration timelines, and gauge ROI. But pilot programs can add expense to a project, making it unaffordable for some.
“If that’s the case, then the best advice is work with a vendor who has experience integrating [the technology],” Heldenberg says. “Use their experience to benefit your business. You won’t have the same hiccups and challenges you would with a less-experienced vendor.”
“While there have been some signs of tightening in consumer spending, September’s numbers show consumers are willing to spend where they see value,” NRF Chief Economist Jack Kleinhenz said in a release. “September sales come amid the recent trend of payroll gains and other positive economic signs. Clearly, consumers continue to carry the economy, and conditions for the retail sector remain favorable as we move into the holiday season.”
The Census Bureau said overall retail sales in September were up 0.4% seasonally adjusted month over month and up 1.7% unadjusted year over year. That compared with increases of 0.1% month over month and 2.2% year over year in August.
Likewise, September’s core retail sales as defined by NRF — based on the Census data but excluding automobile dealers, gasoline stations and restaurants — were up 0.7% seasonally adjusted month over month and up 2.4% unadjusted year over year. NRF is now forecasting that 2024 holiday sales will increase between 2.5% and 3.5% over the same time last year.
Despite those upward trends, consumer resilience isn’t a free pass for retailers to underinvest in their stores by overlooking labor, customer experience tech, or digital transformation, several analysts warned.
"The 2024 holiday season offers more ‘normalcy’ for retailers with inflation cooling. Still, there is no doubt that consumers continue to seek value. Promotions in general will play a larger role in the 2024 holiday season. Retailers are dealing with shrinking shopper loyalties, a larger number of competitors across more channels – and, of course, a more dynamic landscape where prices are shifting more frequently to win over consumers who are looking for great deals,” Matt Pavich, senior director of strategy & innovation at pricing optimization solutions provider Revionics, said in an email.
Nikki Baird, VP of strategy & product at retail technology company Aptos, likewise said that retailers need to keep their focus on improving their value proposition and customer experience. “Retailers aren’t just competing with other retailers when it comes to consumers’ discretionary spending. If consumers feel like the shopping experience isn’t worth their time and effort, they are going to spend their money elsewhere. A trip to Italy, a dinner out, catching the latest Blake Lively and Ryan Reynolds films — there is no shortage of ways that consumers can spend their discretionary dollars,” she said.
Editor's note:This article was revised on October 18 to correct the attribution for a quote to Matt Pavich instead of Nikki Baird.
A real-time business is one that uses trusted, real-time data to enable people and systems to make real-time decisions, Peter Weill, the chairman of MIT’s Center for Information Systems Research (CISR), said at the “IFS Unleashed” show in Orlando.
By adopting that strategy, they gain three major capabilities, he said in a session titled “Becoming a Real-Time Business: Unlocking the Transformative Power of Digital, Data, and AI.” They are:
business model agility without needing a change management program to implement it
seamless digital customer journeys via self-service, automated, or assisted multi-product, multichannel experiences
thoughtful employee experiences enabled by technology empowered teams
And according to Weill, MIT’s studies show that adopting that real-time data stance is not restricted just to digital or tech-native businesses. Rather, it can produce successful results for companies in any sector that are able to apply the approach better than their immediate competitors.
“ExxonMobil is uniquely placed to understand the biggest opportunities in improving energy supply chains, from more accurate sales and operations planning, increased agility in field operations, effective management of enormous transportation networks and adapting quickly to complex regulatory environments,” John Sicard, Kinaxis CEO, said in a release.
Specifically, Kinaxis and ExxonMobil said they will focus on a supply and demand planning solution for the complicated fuel commodities market which has no industry-wide standard and which relies heavily on spreadsheets and other manual methods. The solution will enable integrated refinery-to-customer planning with timely data for the most accurate supply/demand planning, balancing and signaling.
The benefits of that approach could include automated data visibility, improved inventory management and terminal replenishment, and enhanced supply scenario planning that are expected to enable arbitrage opportunities and decrease supply costs.
And in the chemicals and lubricants space, the companies are developing an advanced planning solution that provides manufacturing and logistics constraints management coupled with scenario modelling and evaluation.
“Last year, we brought together all ExxonMobil supply chain activities and expertise into one centralized organization, creating one of the largest supply chain operations in the world, and through this identified critical solution gaps to enable our businesses to capture additional value,” said Staale Gjervik, supply chain president, ExxonMobil Global Services Company. “Collaborating with Kinaxis, a leading supply chain technology provider, is instrumental in providing solutions for a large and complex business like ours.”
However, that trend is counterbalanced by economic uncertainty driven by geopolitics, which is prompting many companies to diversity their supply chains, Dun & Bradstreet said in its “Q4 2024 Global Business Optimism Insights” report, which was based on research conducted during the third quarter.
“While overall global business optimism has increased and inflation has abated, it’s important to recognize that geopolitics contribute to economic uncertainty,” Neeraj Sahai, president of Dun & Bradstreet International, said in a release. “Industry-specific regulatory risks and more stringent data requirements have emerged as the top concerns among a third of respondents. To mitigate these risks, businesses are considering diversifying their supply chains and markets to manage regulatory risk.”
According to the report, nearly four in five businesses are expressing increased optimism in domestic and export orders, capital expenditures, and financial risk due to a combination of easing financial pressures, shifts in monetary policies, robust regulatory frameworks, and higher participation in sustainability initiatives.
U.S. businesses recorded a nearly 9% rise in optimism, aided by falling inflation and expectations of further rate cuts. Similarly, business optimism in the U.K. and Spain showed notable recoveries as their respective central banks initiated monetary easing, rising by 13% and 9%, respectively. Emerging economies, such as Argentina and India, saw jumps in optimism levels due to declining inflation and increased domestic demand respectively.
"Businesses are increasingly confident as borrowing costs decline, boosting optimism for higher sales, stronger exports, and reduced financial risks," Arun Singh, Global Chief Economist at Dun & Bradstreet, said. "This confidence is driving capital investments, with easing supply chain pressures supporting growth in the year's final quarter."