Ergonomically designed handling in dm's textile distribution center
The JumboFlex High-Stack allows users to pick up packages in an upright body position.
Shampoos, toothbrushes and deodorants are not the only products to be found on the shelves of dm stores. The extensive dm range also includes products from the areas of health, nutrition, photography, and baby and children's clothing. The dm stores - which today number more than 3,600 in 13 European countries - are supplied from various distribution centers. There, employees assemble incoming goods for the individual dm stores, ensuring that the wide range of more than 12,500 products is always available to customers.
The textile distribution center in Karlsruhe currently employs around 160 people. The distribution of children's textiles, bathroom accessories and toiletry bags for all German stores and for selected dm stores in Austria, Croatia and Slovenia takes place in an area of just under 11,000 square meters. Every year, around 480,000 parcels in four sizes and weighing up to 30 kilograms are packed and delivered here.
Tripling of dispatches
"Initially, around 800 parcels a day left our storage, but now the average is 1,850 shipments," reports Alexander Fiedler, head of the textile logistics department in Karlsruhe. An enormous increase that the original hall layout could no longer cope with. "From the very beginning, we used the vacuum lifter JumboFlex 35 from Schmalz in combination with a column-mounted jib crane to load the large cardboard boxes," recalls the logistics specialist. But after the loading area was rebuilt, the existing system was no longer optimally designed for the new layout: The length of the column-mounted jib crane was no longer sufficient for the redesigned packaging line, and the stacking height was limited by the system with the universal vacuum lifter.
These challenges were to be overcome by a new system. The aim was to optimize processes on the one hand and to make work even easier for the employees on the other. The loading volume of the trucks was to be used even better, transport costs minimized and the CO2 balance further improved. In addition, the previous combination had ergonomical weak points when used by warehouse staff. Instead of being loaded on pallets, packages were loaded on dollies. This had a negative impact on the workflow, as the logistics manager describes: "The employees virtually had to climb into the roll carts to reach the packages in the back rows."
Flexibility wins
In the search for an ergonomical and at the same time efficient solution, the logistics planners initially also considered partially and fully automated solutions. "These were neither economical nor practical because, for example, we always have to load different types of cartons," explains Fiedler, supplementing, "A manual handling solution gives us the necessary flexibility here and is also cheaper and faster to implement." With the logistics objective in mind, as well as the requirement that the solution be fully accepted by the employees, those responsible at the retail company once again approached J. Schmalz GmbH. The contact with the vacuum expert has existed for several years, so that the Karlsruhe-based company again relied on the constructive and solution-oriented cooperation.
Schmalz had a clear answer to the question of how the transport space can also be used to the maximum upwards: the JumboFlex High-Stack has been specially developed for overhead handling tasks. At the same time, loads from near the floor, for example the bottom layer on the pallets, can be picked up with the tube lifter in a way that is easy on the back. "In our design, we combined the JumboFlex High-Stack with a responsive crane system," explains Michael Schlaich, head of the handling business development process at Schmalz. The concept achieves the necessary flexibility by means of an adjustable vacuum gripper - so that the various carton sizes can be gripped without any problems. Schmalz achieves more comfort and thus an important contribution to the acceptance of the system solution by the employees in the distribution center by means of a silencer box, which reduces the sound pressure level of the vacuum generator. In addition, the vacuum lifter is equipped with a radio remote control that allows users to switch the vacuum generator off and on again directly at the operator handle during work breaks. "This further reduces the noise level and also saves energy," clarifies Schlaich. The coordinated overall concept not only convinced the decision-makers. "We involved the employees on site at an early stage and were able to test the functionality of the JumboFlex High-Stack in a field test," explains Alexander Fiedler.
Ergonomically and safe
Today, the cardboards arrive in the loading area on three parallel roller conveyors. "This layout is possible because even the middle lane can be reached without twisting with the new lifting aid," supplements the logistics manager. The employees stand on a platform about 40 centimeters high, which improves accessibility compared to the past. They stack the packages on pallets up to a height of 215 centimeters with the help of the JumboFlex High-Stack. "Thanks to the long, pivoting operator handle, every storage position on the pallet can be reached in an ergonomically correct posture from the bottom to the top layer," Schlaich emphasizes. The continuously rotating unit provides plenty of freedom of movement and prevents the hose from twisting. This allows the device to be operated flexibly from all directions. To prevent the goods from falling prematurely, the user can only detach them when they are lowered. Only when the user presses the button for lowering the load completely can a second lever be operated to release the vacuum. In addition, the gripper is vented so quickly that no additional force is needed to release the tube lifter.
"The new solution has now been in operation since November 2018 and has fully met our expectations," Alexander Fiedler sums up. Due to the increased stacking height, the loading volume of the trucks can be used much better, thus reducing the number of daily transport trips. The feedback from the employees is equally positive: "They accept the lifting aids very well and praise the responsive nature of the crane system," Fiedler relays his impressions from the shipping area.
With the High-Stack, the second roller conveyor can also be easily unloaded in an ergonomically correct position.
The JumboFlex High-Stack enables optimum use of the cargo space.
Thanks to the long operator handle, every storage position on the pallet can be reached in an ergonomically correct position from the bottom to the top layer.
The employees stand on a platform approximately 40 centimeters high, which improves accessibility.
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