Supply Chain Logistics: Foundational Knowledge for Frontline Workers

Chapter 3: Types of Equipment

Overview of Material Handling Equipment

  • A variety of material handling equipment exists today, ranging from simple hand trucks to advanced automated systems such as wire-guided turret trucks that can exceed costs of $100,000.

  • This chapter focuses on the equipment commonly employed within the supply chain process.

  • Unique requirements for special handling may necessitate specific types of equipment for different operations.

Objectives of Chapter 3

  • Upon completion of this chapter, you will be able to:

    1. List examples of manual equipment.

    2. Identify types of lift trucks.

    3. Recognize types of loading dock equipment.

    4. Describe the function and types of conveyors.

    5. Identify common automated systems utilized in material handling.

Manual Equipment

Hand Trucks (Two-Wheel Dolly)

  • Typically utilized for moving small items over short distances in environments such as storage areas and parts rooms.

  • Not suitable for transporting large quantities of products quickly or for palletized items.

Platform Trucks (Picking Carts)

  • Designed for use in confined spaces to collect items for later dispatch via conveyors to shipping areas.

  • Operated by manually placing products on the platform by the worker.

Pallet Jacks

  • Primarily used for moving single pallets over short distances, especially in limited spaces like trailers or containers.

  • Can be manual or battery-powered.

  • Features include:

    • Front wheels built into fork structure that slides under the pallet.

    • Hydraulic lift to raise the pallet just off the ground.

Industrial Fork Trucks / Lift Trucks

  • Various styles exist for diverse tasks in material handling operations, powered by electricity, propane, or gasoline.

  • Electric trucks, which use on-board batteries, are widely preferred because:

    • Easier maintenance.

    • Environmentally friendly.

    • Quieter than propane or gasoline trucks.

  • Key statistics regarding forklift accidents:

    • Responsible for approximately 85 deaths per year in the U.S.

    • 35,000 accidents leading to serious injury and over 60,000 classified as non-serious.

    • Estimated 850,000 lift trucks operate in the U.S.

Types of Lift Trucks

  1. Stand-Up Counterbalanced Lift Truck

    • Operator stands while driving; offers enhanced visibility of the load and travel path.

  2. Sit-Down Counterbalanced Truck

    • Common in warehouses; can handle loads up to 6,000 pounds.

    • Alternately referred to as forklifts or lift trucks; suitable for high-volume shipping and receiving.

  3. Order Picker

    • Allows the operator to ascend with the load to access elevated rack locations.

    • Useful for retrieving products from locations with partial pallet loads.

  4. Sideloader

    • Handles larger-than-pallet-sized loads; features forks mounted perpendicular to travel direction for side loading.

Electric Pallet Trucks

  • Three primary types exist:

    1. Single Pallet Truck: Operated on foot; approximate speed of 3 mph.

    2. Single-Pallet Rider Truck: Operator rides on the front; typical speed about 7 mph.

    3. Double-Pallet Rider Truck: Designed for picking full cases in large warehouses with many long aisles at floor level.

Specialized Trucks

  1. Narrow Aisle Trucks

    • Designed for rack areas; don’t require wide aisles (requires approx. 8-ft vs. 10-ft for counterbalance trucks).

    • Higher cost; equipped with standing operator platforms with small turning radii.

  2. Very Narrow Aisle Trucks

    • Focus on cubic space efficiency; typically wire or rail guided with turret trucks capable of 180-degree rotation.

    • Used for high stacking in racks, necessitating very flat floors for accuracy at high elevations.

  3. Counterbalance

    • The weight of the truck helps balance the load weight to prevent tipping.

Loading Dock Equipment

  • Specific equipment allows vehicles to approach docks or staging areas safely, which aids in loading and unloading procedures.

Types of Dock Equipment

  1. Scissor Lift or Portable Platform

    • Can be portable or stationary; elevates to trailer height for loading and unloading.

  2. Dock Board/Plate

    • Bridges the gap between the warehouse and carrier vehicles if they are at similar heights.

    • Hydraulic versions can support loads up to 30,000 lbs.

  3. Yard Ramps

    • Used in yards to facilitate access from ground to trailers/containers.

Conveyors

  • Used for transporting products across short distances in various loading and unloading contexts.

  • Categories of gravity conveyors include:

    • Gravity wheel conveyor

    • Roller conveyor

    • Accordion wheel conveyor (portable and collapsible)

Carton Clamp Trucks

  • Equip large rubber-lined clamps to grip and transport bulky items in warehouses, suited for high-load capacities when mounted on standard forklifts.

Specialized Equipment

  • Specific equipment can adapt to different products and packaging with changeable attachments, such as clamps for slip sheets or barrels, maximizing the versatility of machinery used.

  • Equipment examples include:

    • Slip sheet attachments

    • Carton clamp attachments

    • Roll clamp attachments

Yard Lift

  • A specially designed truck features pneumatic tires, enhancing operation on uneven outdoor terrains without disturbing load stability.

Overhead Handling Equipment

  • Aimed at optimizing floor space by transporting items above ground level.

Types of Overhead Equipment

  1. Overhead Traveling Conveyor

    • Movable carriers utilize motorized rails to facilitate transport overhead.

  2. Overhead Crane and Hoist

    • Generally used in maintenance but not frequently in warehouse settings; can be utilized for specific tasks like battery changes.

    • Components include:

      • Runways for crane travel.

      • End Trucks to connect runways to structural elements.

      • Bridge Beam holds the end trucks together.

      • Hoist mechanism for lifting, typically powered.

Automated Conveyor Systems

  • Designed for high efficiency and minimal human intervention in material movement.

Types of Automated Conveyors

  1. Conveyor Sorting Systems

    • Very efficient at sorting cases or cartons via barcode, capable of processing upwards of 10,000 to 20,000 cases per hour.

  2. Vertical Reciprocating Conveyors (VRCs)

    • Used for vertical transport of materials across warehouse levels using buckets or platforms.

Gantry

  • A movable crane with a bridge beam that can lift loads without being restricted to fixed paths, enabling flexibility in usage across the facility.

Automated Systems

Automated Guided Vehicle (AGV)

  • Guided along predetermined paths using wire, tape, magnets, lasers, or paint; operates without human involvement.

Automated Storage/Retrieval System (AS/RS)

  • Large, robot-like vehicle for storing and retrieving loads in high reach areas, capable of lifting to significant heights (100+ feet).

Shuttle System

  • Operating in tandem with AS/RS; multiple shuttles can operate during the same period to maximize throughput and speed.