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INSIGHT Valencia, CA, USA By converting to narrow-aisle storage, PDI Logistics was able to save costs associated with building a new facility. Here, an operator handles product using a narrow-aisle lift truck from Drexel Industries. PDI Logistics, a pharmaceutical distributor and third-party logistics (3PL) provider in Valencia, CA, was using conventional, sitdown, counterbalanced lift trucks to move product in and out of 12-foot aisles in its 138,000square foot distribution center (DC). The 3PL stored 2,500 SKUs of its own product and 600 SKUs of third-party products and shipped to more than 1,000 locations in the US using all modes of transportation. Over a four-year period, PDI experienced an annual growth rate of 100%. Before investing huge amounts of time and money in constructing a new facility, the company considered alternate ways to increase storage density in its existing DC. The solution was very-narrow-- aisle storage. "What prompted our move to very narrow aisles," says Andrew Rosero, consultant and logistics manager at PDI, "was to maximize cube of the available space." Level floors were a concern during redesign, he points out. "We knew that if there was a oneinch variance at the floor, it would mean a onefoot variance from the target load 30 feet in the air." Because it shipped in piece quantities, PDI had to beware of damage resulting from dropping product 30 feet. Nevertheless, drivers had to achieve fast throughput without slowing down. So, PDI caulked the floor, sealed holes, and cut out any metal in the floor that might interfere with a wire guidance system. Currently, PDI has 11 storage aisles with a clear ceiling height of 32 feet. Aisle width is 4 1/2 feet, and length is 220 feet. To speed throughput, the 3PL installed a tunnel bay in the rack system, splitting the long aisles midway. Putaway is random, Rosero says, dictated by the cube of available load openings. "Our retrieval system is designed to pick and batch," he says. "Operators start at one end of the aisle and go down it once; we never have to backtrack. The picking system dictates, in sequence, to which location to go." PDI uses six pieces of powered mobile equipment: a Drexel SLT 30 very-narrow-aisle wireguided lift truck, two Raymond man-up order pickers, a Raymond walkie-rider, and two Yale stand-up riders. The lift trucks service all three specialized storage areas- refrigerated, highsecurity, and aerosol-in the PDI facility. "As opposed to our old facility, our new facility incorporates directed putaway and a cubeoptimized system. We are probably saving 75% in time and motion and now use 66% fewer people to do the same job," says Rosero. Spotlight Narrow-aisle Lift Trucks * Irish manufacturer Aisle-Master recently introduced an LP gas powered articulated forklift capable of working in 78-inch narrow aisles inside a warehouse and outdoors. Because the Aisle-Master truck can operate indoors and out, it can do the work of both electric reach trucks and outdoor counterbalance forklift. www.aisle-master.com * The BGN Series narrow-aisle stacker from Blue Giant Equipment Corp. can reduce product handling and storage costs by accommodating a wide range of pallet sizes. Programmable electronic controls, steel chassis, and sealed drive train are standard. The stacker can lift 4,000 pounds at a height of 200 inches. www.bluegiant.com * Clark Material Handling Co. offers an electric standup, narrow- aisle reach truck with capacities ranging from 3,000 to 4,500 pounds. The truck can handle various pallet sizes and takes up less space than conventional sit-down riders. www.clarkmhc.com * The EASi swing-reach truck extended load handler from Raymond Corp. allows users to place, pick, and move a variety of load sizes in very narrow aisles. The truck can handle loads 48 inches deep by 108 inches wide in aisles as narrow as 68 inches. www.raymondcorp.com * Crown Equipment Corp.'s RR 5200 and RR 5200S Series reach trucks include work relief centers and multi-task controls that increase narrow-aisle productivity. Side-stance design and five- point positioning on the RR 5200 optimize visibility and stability. Single- and double-reach models are available with lifting capacities to 4,500 pounds. www.crown.com * The FR23S-2A 4,500-- pound-capacity, 36-volt electric reach truck from Komatsu Forklift USA Inc. can lift to a height of 402 inches. It includes 360-degree electronic power steering, programmable controls with self-diagnostics, and proportional electronic lift and lower functions. The truck also has a battery discharge indicator with lift interrupt and a safetyglass wind screen. www.kfiusa.com * Hyster Co. offers several varieties of narrow-aisle lift trucks, including single- and doublereach, small-chassis models; straddle-reach trucks; HyStor single-reach trucks; small- and large- chassis order pickers; straddle order pickers; very-narrow-aisle operator-up turret trucks; and very-narrow-aisle operator-down counterbalanced turret trucks. www.hysterusa.com * Landoll Corp. offers two models of narrow-aisle forklifts: the Bendi and PivotMast Series. The Bendi lift truck has a 180degree, front-wheel-steered design for narrow-aisle maneuverability. The PivotMast has a 90-degree rotating mast front sideloader that can stack loads in 56-inch aisles. www.landoll. com * Six-series electric 3,000- to 5,000-capacity reach trucks from Toyota Industrial Equipment include advanced control systems, hydraulic lift motors, and self-diagnostics. Features include wide- view, three-stage masts and 360-degree electronic rower steering. www. toyotaforklift. com * Yale Materials Handling offers several models of straddle-, single-, double-, high-lift reach trucks as well as standard and straddle order selectors. The company's very-narrow-aisle lift trucks have capacities to 4,000 pounds and fork heights to 522.8 inches. www.yale.com * Drexel Industries introduces an operator-down turret truck for use in very-narrow-aisle rack storage. The SLT 30 HLT model turret operates in 66-inch aisles with roller or electronic wire guidance. The three-wheel, 48volt truck has a capacity of 2,650 pounds, transistorized controls with self-diagnostics, an hour meter, and battery discharge indicator with lift interrupt. www.drexeltrucks.com Did you find this material interesting? Do you want more information of this type? Comment via FEEDBACK
Source: Transportation & Distribution By Mary Aichmayr. assistant editor maichlmayr@penton.com
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