The 5 Pillars of a Master Level Overhead Material Handling Solution

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The 5 Pillars of a Master Level Overhead Material
Handling Solution

• Volker Schmitz, Ph.D.
• President, Schmalz Inc.

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PRESENTATION OUTLINE
Speaker Background
Company Overview
Economic Drivers influencing lift assist device
use
(5) Factors driving successful implementations
adoptions
(3) case studies highlighting actual results
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SPEAKER BACKGROUND
PROFESSIONAL

• 25 years experience in Manufacturing in the
  Americas Europe

• 17 years experience in Factory Automation

EDUCATION

• Masters Degree in Economics from Johns Hopkins
  University

• Harvard Business School General Manager Program

• Ph.D. in Business (Global Contract Pricing)

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COMPANY OVERVIEW

• Established 1910
• Ownership Privately held - 3rd Generation
• Market importance World's leading supplier of
  vacuum technology for automation and
  material handling tasks
• Sales Growth double digits every year (except
  2009)
• Employees 800 worldwide, including 13
  trainees
• Subsidiaries abroad 15 countries
• Intl. Sales partners 45 countries
• Innovation indicators 180 International
  Patents
• 8 of annual revenues spent on R D
• Distinctions ENERGY POSITIVE (own Wind, Solar,
  Hydro, wood chips from own forests bio fuels)
• ISO 90012000 (since 1994)

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(4) Business Units using VACUUM
Overhead Lift Assist Devices Cranes
Automation Components
Only company who is active in both fields
EOAT Robot Tools
CNC Machine hold down clamping
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Ignore at your own Peril
Case order picking of a 70 lbs oversized
box Great Ergonomic Form, but its still a
Worker Comp Claim waiting to happen
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REMINDER STATISTICS
2009 55 Million Working Days
Lost (29 due to MSDs) 82 Billion Cost
in Wages and lost Productivity
Largest factor are musculoskeletal disorders
(MSDs)
Over 32 million workers 25 of US workforce
exposed to body twisting or bending for more
than half their time at work
Sources National Safety Councils Injury Fact
Report (2011 Edition) This figure does not
include medical, administrative, damage to
vehicles, fire loss and employers uninsured
costs. Ref. Occupational Information Network
and Occupational Employment Statistics data BLS
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COST DRIVERS

• Labor Costs up 500 in last 100 years trend
  continues
• 30 Million Worker shortage coming by 2030
• Aging Workforce (2020 25 of workers will be
  over 55)
• 40 in W. Europe
• Warehouse labor turnover among the highest
• ANSWER Need to make jobs less physical
• increase productivity
• existing staff retention
• accommodate aging staff
• expand eligible labor pool to pick from

 
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WHAT ARE WE TALKING ABOUT Overhead Lift Assist
Devices
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5 FACTORS for implementation adoption
Supplier Warranty Guarantee
GOAL 80 adoption rate, 80 risk reduction
50 productivity gains
Include Operator training
Customer talking to Factory
Involve Operators (80/20)
Run off at Factory
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Case Study 1 Effective at risk cost reduction

• Vacuum Tube Lifter used as a Logistics Lift
  Assist Device
• (example airport baggage ramp handling study)
• 50 reduction in injury / workers comp claims
  after 1 year
• Vacuum Tube Lifter capable of handling 90 of
  all baggage processed
• Practical result 72 useage by the staff for
  all baggage processed

Source independent study of Munster airport
baggage handling staff (2010)
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Case Study 1 (cont.)
Percent
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Case Study 2 Higher productivity at low
investment cost

• Vacuum Tube Lifter used as a Logistics Lift
  Assist Device in a large Internet retailer DC
  facility (overseas)
• (3) Systems handling larger sized boxes for
  outbound shipping
• 55 Productivity
• (thru put) increase
• 50 reduction of
• personnel (re-assigned)
• inc retention satiesfaction

Note Representative Picture only
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Case Study 3 Higher Quality Standards

• Custom style lifter (with powered rotation)
• (2) Systems handling jet engine composite outer
  housing sections
• 4 employees 1
• Av. 2 damaged housings / M
• (cost 800,000 total cost/M)
• Now 0 after 12 months
• Better retention work
• environment feedback

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• Thank you for attending this session.
• If you have any questions, input or feedback
• please feel free to contact me.
• Dr. Volker Schmitz
• President
• Schmalz Inc.
• 5200 Atlantic Ave.
• Raleigh, NC 27616
• Tel [phone]
• Cell [phone]
• volker.schmitz_at_schmalz.us
• www.schmalz.com