VNA trucks are designed to operate in aisles from 1650mm. They allow for more racking within the operational space and since more racking means more pick locations, a greater number of SKUs (stock keeping units) can be stored within the space. The upshot, potentially, is up to 50% more warehouse capacity.

 

However, additional capacity will inevitably give rise to a different forklift fleet profile, since operating hours and maintenance will be reflected in the capability of the fleet, which makes it important to get it right first time when it comes to truck selection.

Narrow aisles allow the warehouse to increase its storage density while still allowing 100% stock selectivity. There is a requirement to move higher volumes quickly and safely while avoiding congestion and bottlenecks. An obvious consideration is that trucks should be capable of lifting high enough to cope with the height of the racking. Equally important, is the need for trucks to elevate quickly and smoothly, with sufficient load capacity, so truck flexibility is a prime consideration.

Yale’s VNA trucks have features that support these more advanced warehouse operations. Its patented hydraulic system, for example, means the operator can undertake synchronised tasks such as traversing, rotating and operating the auxiliary lift while simultaneously lifting the cabin.

Tackling congestion

When business levels are such that the warehouse load seems to be ever increasing, adding more trucks may be too simplistic an approach. If the aisles are already occupied, this can lead to hold-ups and diminishing productivity levels. It is important to take into account congestion and its effects, even on a lightly-loaded warehouse.

Yale’s Paul Smith says: “The size of staging and marshalling areas, how they are used and what effect they have on free movement of pallets, also plays an important part in the smooth operation of the facility; they must be sized correctly for the projected throughput.  

“Similarly, possible bottlenecks at touch points, such as Pick and Drop areas at the ends of racks and packing and wrapping areas, should be factored in and an assessment made of the traditionally complex and high cost order-picking environment.  

“The location of goods stored, the picking time of a truck at a particular location and the overall length of cycle need to be determined so that fleet managers can review options and their likely impact on the warehousing operation in order to determine the most cost-effective solution.”

Ergonomics

Due consideration must be given to operator safety, comfort and well-being. Raising the operating position, for example, allows better visibility of the pallet at all times and enables the driver to perform piece picking when required.

For operator comfort, cushioned floor space to absorb vibration and operator presence foot pedals play a key role in decisions around fit-for-purpose trucks. Depending on the application, the ability for the operator to sit or stand offers flexibility. This can be achieved with trucks that have a 3-way adjustable forward-mounted controls arrangement or seat-side located joystick controls positioned vertically or horizontally.

Informed decisions

Once problems have been identified, the debate centres on what to change to improve productivity or reduce costs. The options can only be investigated properly if fleet managers can access relevant data. Yale has developed a simulator to help in the selection of equipment for their application. A sophisticated software tool based on advanced mathematical modelling, the Yale Warehouse Simulator combines real data and tested assumptions with the additional input of experience and know-how to identify the precise make-up of the fleet required to match the operational requirements. 

This kind of software can add value to the decision making process. It can, for example, calculate the size and mix of fleet required to move a prescribed number of pallets within specific utilisation limits or determine current fleet performance in terms of hours used. If these are excessive and placing a burden on maintenance requirements, a solution can be modelled to bring hours down to within reasonable limits while still satisfying throughput requirements. 

Paul Smith concludes: “Software simulation offers a major benefit in simplifying the decision making process.  However, it should be viewed as part of a toolkit of methodologies and the data it provides used in conjunction with expert advice from the manufacturer/distributor to achieve a solution that will meet all objectives.”