Sharp Interpack Reduces Forklift Damage Thanks to ShockSwitch

Sharp Interpack is one of the world’s leading packaging companies. At its site in Yate, Bristol, the company manufactures a range of plastic trays for the food industry. Karl Traynor, Logistics Manager at the site runs a warehouse storing both raw materials and finished goods. The warehouse is run 24/5, with occasional weekend working and the three man-aloft trucks move products in and out of the narrow aisle racking.

Until 12 months ago, there were occasions when, due to lost steering, the racks, trucks and sometimes products were damaged. Unable to identify who was responsible, Karl began looking for ways reduce damage and maintenance costs within his warehouse. Aware of the Health and Safety implications of driver injury, he was also looking for ways to encourage his drivers to take more responsibility for their accidents and work together to help reduce accidents.

During his research, Karl came in contact with Lamerholm Electronics, who supply the ShockSwitch Impact Manager RFID system. This is a real-time link between a forklift truck in the plant and a PC in the office and collects data regarding use of the truck.  

“It was important for both health and safety reasons as well as improving productivity within the warehouse that the drivers take responsibility for any accidents.” explains Karl. “ We needed to be able to identify when and where the damage was occurring and who was responsible. Once this was possible, we could look at aspects such as driver training, ensuring procedures were properly adhered to and improving safety practices throughout the warehouse.

The ShockSwitch Impact Manager RFID system was just what was required.

The ShockSwitch Impact Manager RFID is attached to the forklift truck and transmits event data via a wireless network to the accompanying software. An unlimited number of trucks can be monitored and programmed to send data immediately an event has occurred.

One of the main features of the Impact Manager RFID is a patented, fully adjustable, 360° impact sensor is an integral part of the system and unique in the industry. Once a collision is detected, the time, date and driver ID are recorded and transmitted immediately for investigation and analysis.  In addition to monitoring and recording, the ShockSwitch Impact Manager  RFID can be programmed to immobilise the truck once an impact has occurred, optionally sounding the ShockSwitch siren or truck horn either continuously or for a specified period of time. This is a particularly useful safety feature to alert other personnel to check for injury. The trucks can also be completely disabled.

For Karl at Sharp Interpack, the ShockSwitch Impact Manager RFID also provides a convenient means to control access and identify specific users of the trucks. By coding a simple to use iButton operator’s key, only authorised key holders are able to activate the ignition system. The software provided with the system also enables details including relevant certifications held to be logged and notification is given when these are due to expire. Maintenance can also be easily scheduled using the software, with alerts being issued when required.

Using the wireless data collection system also saves management time and any number of reports and graphs can be easily generated for further analysis of driver safety, utilisation, and maintenance schedules.

Sharp Interpack were also very impressed with the technical expertise of Lamerholm’s engineers and how they quickly got to grips with the problems. Due to the fact that the warehouse is equipped with high storage racking, up to 15 metres high, and Sharp Interpack runs man-up forklifts in the very narrow aisles, not only was it important to monitor collisions on the ground, but also any impacts that may occur when the cab is raised off the ground. To accommodate this request, Lamerholm installed two impact sensors, one on the base unit and the other on the cab. In this way, any knocks or damage could be identified and repaired quickly.

“We have seen a dramatic decrease in the number of collisions and a reduction in the amount of damage caused to products and the expensive high bay racking is boosting our bottom line.” explains Karl Traynor. “Also, our forklift operators have started to take ownership of any accidents and so overall performance is improving.”

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