Closed Pallet Handling with Counterbalanced Stacker
A leading chemical process manufacturing industry constantly faces challenges in closed pallet handling with conventional stackers. Here’s how AVCON counterbalanced stacker provided a simple yet innovative solution to solve vehicle loading unloading and pallet stacking application and reduce recurring cost of forklift hiring charges.
A leading chemical industry specializes in lubricants process and manufacturing for their domestic and international market. With time bound assignments and continuous inwards outward material movements management continuously seeks ways to enhance operations and meet project timelines. However, like many manufacturing companies, they encountered challenges in optimizing their material handling processes.
Challenges
Customer’s premises were crowded by multiple outward assignments pending for loading inside vehicle and inward material manually unloaded by workers blocking pathway for finished goods dispatch. Due to constraints of have single loading / unloading point deliveries were slowed down and dependent on expensive forklift hiring.
Safety Concerns: The existing material also posed safety risks to workers due to space constraints for forklift movement and human passage through the same bay.
Customer team as a result lacked real-time visibility into their dispatch schedules, making it difficult to track inventory, monitor equipment performance, and identify potential issues proactively.
Solution:
To address these challenges, customer approached us to design and manufacture a counterbalanced stacker without front legs to handle all type of pallets available.
Customer invested in counterbalanced type design not only for their pallet stacking process in for storage in heavy duty racks but also for pallets transportation and vehicle loading unloading.
With selection of counterbalanced stacker for their application the procedure not only become safer compared to manual loading also became easy for usage by every skillset worker with single person operation. Due to flexibility of lifting / lowering height loading and unloading of all sizes of pallet is achieved using stacker.
With compact design and ease of operation for driving equipment usage has achieved maximum utilization of operational space.
Before
After
By adopting AVCON’s counterbalanced stacker, the company addressed these challenges, improved operational efficiency, and achieved significant cost savings, ensuring smooth material handling processes and safer work environmentsResults:
With incorporation of counterbalanced, company achieved 3 times faster turn around time for drum pallet handling.
Due to basic skill set required for operation and multiple safety driving features in counterbalanced fully electric stacker we have eliminated multiple possibilities of accidents or unsafe loading patterns. Workers feel safe in handling of counterbalance stacker and we have achieved zero accidents in handling drum pallets from truck and loading the same on pallet racking.
Usage of counterbalanced stacker reduced company’s cost of forklift hiring and labour to practically zero with no outsourced dependability for factory material inward and outward process.
Implementation Process
The implementation began with a thorough assessment of the factory’s layout and workflow. Based on this analysis, AVCON developed a tailored counterbalanced stacker. Training sessions were conducted to ensure smooth adoption, focusing on safety protocols and efficient usage.
Key Benefits
- Enhanced Efficiency:
- Threefold improvement in turnaround time for drum pallet handling.
- Streamlined loading and unloading processes.
- Improved Safety:
- Elimination of unsafe loading patterns.
- Achieved zero accidents in pallet handling and material transportation.
- Cost Savings:
- Eliminated dependency on costly forklift rentals.
- Reduced labor costs associated with manual material handling.
- Operational Flexibility:
- Compact design ensured better space utilization.
- Adaptable to various pallet sizes and heavy-duty racking requirements.
Conclusion:
This lubricant manufacturing company successfully transformed their closed drum pallet material handling operations through the elementary adoption and process optimization. By addressing inefficiencies and enhancing safety they were able to streamline their operations increase productivity and remain competitive in ever evolving manufacturing sector.
This case study showcases power of strategic decision making and attitude to create a workplace observing complete safety guidelines resulting in business success.