Cooper B-Line is a global manufacturer of both standard and customised enclosures. Manufactured at their factory in Highbridge, UK, the company supplies its products primarily to the communications and computer industries including many blue-chip organisations.
In the 240,000 sq/m factory, goods and parts are moved around the warehouse and loaded onto lorries and containers using 4 forklift trucks . 2 gas powered and 2 electric charged. However, safety issues were a concern as damage to products, equipment and trucks was going unreported and with 50 sets of keys on the shopfloor at one time, it was proving impossible for the management to identify the causes, times and those responsible for the incidents. The cost of repair and maintenance of the warehouse racking was an important factor, as was the fact that unreported racking damage could prove a health and safety concern as goods could fall and cause injury. With sometimes as many as 2-3 incidences a day, the management knew they needed to take action.
Looking to Reduce Damage by Forklift Monitoring
After looking at all the options available for controlling and monitoring usage of the forklifts, Cooper B-Line chose the ShockWatch ImpactManager from Lamerholm.
ShockWatch ImpactManager is a compact unit that is mounted directly in the vehicle cab. It detects impacts and records event details such as date, time and driver ID. Impact monitoring capability comprises a patented, fully adjustable, 360° impact sensor. Once a collision is detected, the time, date and driver ID are recorded and stored in the memory for downloading, further investigation and analysis. In addition to monitoring and recording, the ShockWatch ImpactManager can be programmed to immobilise the truck once an impact has occurred.
At the heart of this innovation is the proprietary software package. As the information is critical to the running of the warehouse, ImpactManager software has been configured to set equipment operating parameters, record operator activity, track operator certification, set equipment maintenance schedules, and disable the equipment upon impact. The software ensures timely, reliable, and accurate operator and equipment data allowing better decisions to be made to reduce damage-related costs.
Improving Performance at Cooper B-Line
Clive Woodrow, Integration & Projects Manager, recognised that the most pressing issue he faced was to stop unauthorised users driving the trucks and once this problem was tackled then there would be a reduction in the number of accidents and amount of damage. The Lamerholm system chosen, the ShockWatch ImpactManager ID, uses an access control system that only allows authorised drivers to operate the trucks and records the time and date of any impact. Vehicle access is controlled via pre-programmed iButtons. Authorised drivers simply activate the truck using the iButton control and they are immediately identified through the software that also tracks current certification in line with Health and Safety requirements.
In the 6 months since installed on the system, there has only been 1 impact in the factory and that was reported with 10 minutes of the incident occurring.
Not only have I been delighted with the how quickly the system was installed, but also how quickly issues with driver safety were resolved. It has been a valuable deterrent to ensure that any hits are reported immediately, as drivers know they can be identified through the software. Using iButton technology, there are also no passwords to be remembered or shared.. says Clive.
The system is now been installed on the 2 gas-powered trucks and the key control system is being used on the company.s pallet movers.
And it wasn.t just the reduction in damage that helped cost savings. .We were also able to monitor efficiency of the trucks and pallet movers, particularly on the nightshift and when they were being operated out of hours. Our operators have greatly improved efficiency and we can ensure all the equipment is being fully utilised.
Payback Time
The ShockWatch ImpactManager has been installed since November 2006 and Cooper B-Line expects to see a monetary payback by November 2007. However, immediate payback is the respect the drivers are now showing the equipment and the greater efficiency within the warehouse.
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Author:
Edwin Elliott. Lamerholm Electronics Ltd. The Pixmore Centre, Pixmore Avenue, Letchworth,
