Top 10 Warehouse Hazards

Hazards exist in any workplace.  Warehouse hazards, though, create more accidents because of the massive quantities of products of all different sizes, shapes and weights stored on shelves, floors and anyplace else someone can find a place to put a box, pallet or carton. Per the National Institute for Occupational Safety and Health, the biggest warehouse hazards include:

• Overexertion Injuries – these occur when workers lift items that are big and heavy for a long period of time resulting in excessive physical effort. Injuries can occur to joints and ligaments. Also, in the warehouse, workers walk to pick orders. The trip length between picks can be quite long, especially if the warehouse is not organized properly. Properly planned pick paths, SKU rationalization and appropriate slotting of SKUs can help to cut down the length the worker must travel to fill orders.
• Lifting and Handling Materials – Improper handling of boxes, pallets, cartons and items can cause strain and injury to different parts of the body, especially the back. Heavy, big objects should be placed in the “golden zone,” where workers do not have to bend, reach or lift above their shoulders or below their waists.
• Slips, Trips and Falls – Each year, more than 8 million Americans will be treated in emergency rooms due to an accidental fall. If items are store haphazardly within the distribution center, such as sticking out too far from a shelf, or placed in the middle of an aisle, workers can easily injure themselves by tripping over or running into these items. Making sure floors are dry and slip resistant can prevent slips, trips and falls.
• Falling Objects – Items not stored properly can fall and inure someone. If the storage racks do not have end-caps, items can just slide right out onto the floor causing injury. For example, UNEX Keg Flow features side rails to help steady heavy beer kegs, a custom hanger to provide fractional pitch and a high roller stop so that kegs don’t topple off the end.
• Forklifts – Most accidents occur in a warehouse at/with the docks, forklifts, conveyors, storage units and manual lifting/handling. Forklifts can overturn or they can be overloaded, subjecting materials to falling off. Accidents between forklifts of between a forklift and another surface can cause serious injury. Statistics show that 1 in 10 forklifts are involved in an accident each year. Operators need to check hydraulic levels, tire pressure, engines, controls, steering and brakes each day to make sure all are working properly.
• Loud Noise – Tools, equipment and machinery that makes loud noises can cause hearing loss. Ear protection should be work by workers in this environment. The single biggest source of noise and threat to workers’ hearing is often the radio they carry. In order to be heard above the din around them, the radio must be at least three decibels louder. But dB Blockers are designed to integrate with all modes of communication, so workers can communicate and hear clearly at all times while staying protected.
• Unstable Packaging – Packaging is being made more flimsy in an effort to reduce cost and waste. As a result, things like cardboard boxes are being replaced by cardboard slats covered in plastic, which are more unstable when loaded. Workers need to pay particular attention to avoid dropping contents or injuring themselves by lifting flimsy packaging.
• Don’t Overload Carts – Carts help carry products or cartons during picking operations. Make sure that the cart can handle the load and that the items stacked on the cart are not above the picker’s level of vision so you won’t bump into any items, causing the cart to spill.

Ergonomics is important in the warehouse for safety as well as productivity. Products need to be handled correctly in picking and packing operations to reduce the risk of injury from improper handling. That’s why UNEX emphasizes ergonomics in all of its solutions- whether it’s picking from the Golden Zone or keeping tools within easy reach at a packing station, our solutions take into account these warehouse hazards and minimizes them for a safer, healthier, and happier workforce.

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source http://www.unex.com/top-10-warehouse-hazards/

No-Shave November

For the past few years, UNEX has participated in Movember in order to raise awareness around men’s health issues and to raise money for preventative and educational programs. One of these health issues is cancer, a disease that kills 22,000 people worldwide every day- half of which are preventable. While we’re proud of the money we raise (and the mustaches we grow) for Movember, we recognize that there is far more work to do. That’s why UNEX Manufacturing and its employees have decided to take part in No-Shave November.

The goal of No-Shave November is a simple one- to raise awareness and money for cancer research and treatment by embracing our hair and allowing it to grow wild and free. Instead of spending money at the barber shop, stylist, or waxing studio, participants instead donate to No-Shave November to support its funded programs, which include the Prevent Cancer Foundation, Fight Colorectal Cancer, and St. Jude Children’s Research Hospital. These organizations are solely focused on the prevention and early detection of cancer and the development of a cure.

Many- if not all- of our lives at UNEX have been impacted by cancer in one way or another. We have learned from our experiences that no one should be left to take on the disease alone, and that rallying our community around friends and family dealing with the realities of cancer gives more than just financial assistance- it provides hope, strength, and camaraderie. We want to do everything within our power as individuals, as a company, and as a family, to provide that hope and strength to as many as possible.

That’s why UNEX Manufacturing is donating $1,000 through our No-Shave November team page and matching individual donations up to another $1,000!

 

Our fundraising goal for No-Shave November is $2,500, but we hope that our company match (along with your help) will allow us to smash through that goal and make as big an impact as possible. We encourage you all to join us on our No-Shave November journey. Here’s how you can get involved:

1. Head over to the UNEX team page.
2. Click “Make a Donation” on the right hand side of the page- or just follow the link.
3. Donate what you can.
4. Click “Share this Page” on the right hand side, and let your friends and family know how they can participate!

Of course, you can always sign up, start your own team or organization, and begin raising money on your own. But remember- donations through the UNEX team page will be matched!

We’re also encouraging our team members to share their stories about how cancer has impacted their lives. The most important thing we can do this month is show survivors and family and friends of lost loved ones that they are not alone, that we share their struggles, and that we are there for them, ready to provide assistance in any way possible. We will be sharing those stories on one of our social media pages as they come.

We hope that you will join us in this fight.

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source http://www.unex.com/no-shave-november/

UNEX Exhibits Industrial Carts and Flow Cell Solutions at The Assembly Show

UNEX Manufacturing, Inc., the trusted industry leader in providing innovative order picking solutions, will be exhibiting their advanced order picking and lineside storage solutions at The Assembly Show in Booths 1231 and 1331 at the Donald E. Stephens Convention Center in Rosemont, IL. These solutions help manufacturers improve their assembly lines by better managing materials in these areas, helping to improve productivity, quicken delivery schedules and enhance customer satisfaction.

“Manufacturers need to make sure that when the products arrive at the lineside assembly areas that they are labeled clearly and packaged well so that the contents can be easily identified. The less time it takes the assembler to visually recognize the part needed, select it, pick it and prepare to install it, the less time is wasted having to search for an item. Employees will be less frustrated not having to search for a particular part to finish their assembly,” said Brian C. Neuwirth, VP of Sales and Marketing, UNEX Manufacturing.

Both booths will showcase some of the following equipment, with one booth focusing more on mobile solutions:

UNEX lineside storage solutions improve picking operations within assembly. When customization is high in an assembly operation, having the ability to store additional SKUs in the assembly area means pickers don’t have to travel to find the right part, speeding fulfillment rates. Efficiencies and productivity are increased as well.

UNEX Flow Cell workstations help with subassembly processes by bringing small parts that are to be incorporated into larger manufactured products together, providing a workbench on which to assemble parts. Components are stored in cartons or totes on the workstations, which also can be equipped with overhead toolbars, monitors and work instructions.

UNEX industrial carts are used to move materials, parts, boxes and components from one location to another within assembly operations. Carts are available with open shelving or racks to hold cartons or parts, improving picking operations and boosting productivity. UNEX will display a prototype version of its newest industrial carts to solicit feedback from the Assembly Show audience and to demonstrate the flexibility that makes Flow Cell an industry leading solution.

Other UNEX Flow Cell products will be displayed to show how they can help maximize space, diminish movements with angled shelving, reduce waste with a lean focus and support FIFO methodologies so components never reach their expiration date.

The Assembly Show takes place on October 24 – 26, 2017, in Rosemont, IL. Visit UNEX at Booths 1231 and 1331 to better understand how the company’s solutions increase productivity and reduce manufacturing lead times.

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source http://www.unex.com/unex-industrial-carts/

The Warehouse Slotting Game

In today’s fast-paced world of getting orders into the hands of consumers and businesses seemingly instantaneously, warehouse managers have put a premium on the picking process. No picking technology can handle everything, whether its picking full pallets, partial cases or individual pieces, so it’s important to let the profiles of SKUs and orders lead you to the right solution.

Many modern warehouses use a mix of different solutions for picking orders dictated by product type, product velocity and order type. To make the best selection of picking solutions, a thorough understanding of your customer service requirements blended with SKU profiles can help you pick the best system for the job. Not every warehouse needs automated picking solutions, which may save on labor, but the added cost and maintenance can be prohibitive.

Many warehouses can speed the picking process by slotting SKUs intelligently, which involves reviewing:

• the type of product (weight, size, shape)
• how often the product is touched
• the pick path (the distance an order picker would need to travel to get to the location, and how accessible the location will be once the picker gets there)
• the size of the pick face (ensuring the product will fit into the right location)

Once this information is gathered, many UNEX customers use our powerful warehouse slotting tool, SKUBE that analyzes the product data and movement, then suggests SKU locations. It determines what should go where to maximize efficiency and ensures products move easier and faster in the order picking process.

Proper warehouse slotting can solve the problem of SKU proliferation, which occurs quite often in the food and beverage space, among others. As distributors handle more and more products – from craft beer to international foods – running out of space in the warehouse can be an issue. SKUBE assigns each product to pallets, carton flow or shelving units based on its analysis of movement so that items are stored in the right location for the fastest pick.

Warehouse slotting is a complex exercise that takes skill, knowledge and the right tool to drive warehouse efficiencies, save space and speed order picking. It is not a game of chance.

UNEX’s order picking solutions for piece, case, and/or pallet picking can speed order picking operations for most distributors – and without the maintenance responsibilities of automated systems. UNEX Pickologists work closely with clients to profile their SKUS to help them select the right picking solution for their operation. Then deploy the picking solution to improve productivity and increase accuracy – making your picking operations efficient and productive.

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source http://www.unex.com/warehouse-slotting-game/

What’s Brewing in Beverage Distribution?

There’s no disputing that beer is big business. According to Nielsen, “In the U.S., Americans spent more than $37 billion on beer at Nielsen-measured retail stores in the year-ended Feb. 25, 2017.” From the King of Beers to independent craft brews, the number of brands, styles and flavors of beer continues to proliferate, creating a massive, diverse, high-volume product category. Beer drinkers are spoiled for choice, but still clamor for the new and unfamiliar.  As Beverage Dynamics’ Kyle Swartz described the phenomenon, “Many consumers nowadays never even revisit good beers. That’s an actual trend being reported by brewers: people will drink a beer knowing they’ll never have it again. They only want what’s new to them.”

That puts big pressure on beverage distributors and processors, who must efficiently store, handle and ship this ever-expanding jumble of SKUs, not to mention deal with the mashup of packaging types, materials, sizes and shapes, each of which contains date- and temperature-sensitive pressurized contents.

Whether it’s bottled, canned or kegged, beer is a challenge to handle and distribute. And while processors and wholesalers may face slightly different challenges – in general, processors handle fewer SKUs but in larger volumes, and wholesalers handle a larger number of SKUs, often in lower volumes, or at the case level, or even in individual quantities – both are faced with storing and processing huge amounts of product efficiently within existing warehousing space.

That’s why UNEX creates space-saving beverage storage and handling solutions that ensure accurate inventory management; fast and easy SKU identification; labor efficiency and safety; and robust, economical operation. Here’s how:

• Gravity flow systems are dynamic storage and retrieval systems that are powered by natural gravitational mechanics, decreasing energy usage and lowering operational costs.
• Sloped rows, racks and shelves get stored product off the floor and into organized, accessible, high-density locations, reducing the amount of space, time and labor needed for fulfillment.
• Kegs, cartons or pallets are loaded into the high end of pitched lanes, and product is dispensed from back to front via controlled downward glide to the pick station, an orderly flow that optimizes FIFO inventory turnover and relieves congestion by separating load and pick aisles.
• Dispensed product is ergonomically positioned, highly visible, and easily identifiable, enhancing worker safety and increasing pick speed and accuracy.
• Systems are highly fluid, flexible and configurable, allowing responsive adjustments to accommodate changing product specs, applications or operational demands.

Gravity flow solutions from UNEX comprise a range of robust, durable keg-flow, carton-flow, and pallet-racking systems, including Span-Track, the engineered-to-order keg-flow system that makes easy work of heavy, hard-to-handle kegs.

Want to tap into the latest beer and beverage distribution solutions? See UNEX in Booth 921 at NBWA’s 80th Annual Convention and Trade Show Conference, October 8 – 11, 2017 in Las Vegas NV. Cheers!

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source http://www.unex.com/beverage-distribution/

UNEX Exhibits Order Picking Solutions at NBWA Show 2017

UNEX Manufacturing, Inc., the trusted industry leader in providing innovative order picking solutions, announces the company will be exhibiting its innovative order picking and material handling solutions in Booth 921 at the upcoming NBWA Annual Convention and Trade Show that takes place October 8 – 11, 2017 in Las Vegas. UNEX solutions help beer distributors make better use of their warehouse space, increase pick rates and speed throughput.

“As the craft beer boom continues, beer wholesalers and distributors must find ways to accommodate a growing number of SKUs in a limited space,” said Brian C. Neuwirth, VP of Sales and Marketing, UNEX Manufacturing. “Fulfilling orders as quickly as possible without damage to the products, whether packaged in cases or in various sizes of kegs, will keep the beer flowing and customers satisfied.”

UNEX Manufacturing will be exhibiting the following equipment designed for the beverage industry in Booth 921 at the NBWA show, showing distributors how to better organize their warehouse to improve visibility, accessibility and pick rates with:

• UNEX Keg Flow – A specially designed version of UNEX’s patented Span-Track that features side rails to help steady the heavy kegs, a custom hanger to provide fractional pitch and a high roller stop so that kegs don’t topple off the end. Angled label holders make product information perfectly visible to order pickers.
• Span-Wheel Bed – A universal bed of carton flow designed with UNEX’s patented Hex Hub wheels that offer maximum flexibility for a rapidly changing inventory of SKUs. Span-Track wheel beds are proven to increase throughput up to 150% to ensure beer and spirits distributors can keep up with ever-increasing demand.

UNEX solutions offer a greater storage density so distributors can handle more SKUs, picking and loading from either side of the rack for improved productivity and heavy-duty construction of racks so heavy products can be kept off the floor for better material handling. We look forward to seeing you at the NBWA show!

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source http://www.unex.com/unex-nbwa-show-2017/

10 Techniques for Order Picking Accuracy

Order picking is a numbers game…

and every second you can shave off throughput cycles, every uptick you can achieve in accuracy levels, every square foot of space you can optimize, and every penny you can save on costs translates into significant increases in efficiency and customer satisfaction.

The trick is to figure out where to find those tiny sources of error and waste and how to address them in ways that build customer confidence and contribute to bottom-line profitability.

The first step is always to assess all facets of your operation – including your processes and your culture – to determine whether there are embedded environmental obstacles that are contributing to systemic inefficiencies:

• Are your processes regularly tested and updated?
• Are there mistakes or gaps in prescribed methods or process documentation? Are workers resorting to work-arounds in an attempt to avoid built-in errors?
• Does your culture discourage questions or dissent?
• Or does honest, open communication flow both up and down?

Holding regular staff meetings (preferably with lunch and/or snacks provided) can encourage workers to share candid information about problems they encounter as well as ideas for improvement. Listen carefully, openly and positively. The folks on the front lines have the knowledge you need. Let them help you.

Here’s where the numbers come into play. To boost order picking accuracy and productivity, try these 10 techniques that can improve your odds:

1. Encourage friendly competition. Just about everyone has a competitive streak, so why not create a game or contest by posting employee throughput levels? Small, even silly prizes can contribute to the fun. Just be sure the competition stays friendly. No gloating or shaming allowed.
2. Embrace baby steps. Most improvements will come incrementally, a result of tweaks in the process, better use of technologies, or upgrades in tools or training. Work with your staff to identify and try innovative adjustments.
3. Weigh in. Implementing a weigh scale and digital verification system is one of the fastest, easiest ways to verify order picking accuracy in a large percentage of your orders.
4. Hands off the documents. Manual document handling and insertion creates significant potential for errors and waste. Using a portable document inserter (or an automated printer and inserter system) instead is a high-speed, low-cost, low-risk solution.
5. Follow the light(s). Pick-to and put-to indicators, used with goods-to-person technologies, provide easy-to-follow visual direction, which maximizes picking speed, improves order picking accuracy and even improves ergonomics.
6. Make a statement. When you’re not use goods-to-person technologies for picking, hands-free voice picking is a good solution. Headset audio directs the picker to the correct location and directs the quantity to be picked. After making the pick, the picker audibly verifies the SKU and quantity. While voice picking typically increases throughput speed only slightly, it significantly increases accuracy.
7. Play the slots. Grouping similar or related inventory items together – slotting – reduces search-and-travel time to increase speed and order picking accuracy.
8. Count on the eye in the sky. Visual scanning technology has down in cost and up in quality. By inspecting SKUs contained in each picked order for accuracy, and diverting questionable order to quality checkers, visual scanning systems reduce labor costs and improve overall accuracy, especially when dealing with small items.
9. Put WES in control. Supplementing your WMS or WCS with WES software can smooth the operational peaks and valleys among your different zones, which can reduce both equipment and labor requirements.
10. SKU maps. Active light grids map SKUs into location-based cells, then preempts errors by using light and audio alarms to alert pickers when they are in the wrong SKU location.

The goal of any picking process is to reduce the number of touches per item, with accurate one-touch picking as the ideal. UNEX offers unique solutions that can help you improve your numbers in your own distribution center. From lines picked per man-hour to order-picking accuracy to warehouse capacity to on-time order shipment, UNEX helps distribution centers improve efficiency for greater customer satisfaction and bottom-line profitability.

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source http://www.unex.com/order-picking-accuracy/