WERC surveys estimate of less than 15 percent of the items in a typical warehouse are slotted correctly and only 31% of warehouses that are surveyed think they have efficient slotting. Subsequently, most warehouses are spending 10% to 30% more per year than they should because the warehouse is not properly slotted.

The advantages of proper product slotting are: Reduced picking labor requirements by locating product in the optimal pick sequence and reducing travel paths. Reduced replenishment labor requirements by matching product unit loads to the appropriate size storage slot for forecasted or historical demand. Reduced response time and improved flow by balancing workload among operators. Increased picking accuracy by separating similar products to avoid proximity picking errors. Reduced possibility of injuries by placing product in its ergonomically best location. Reduced product damage by organizing heavier product first in the pick path, ahead of crushable product. Delay capital expansion by continuing to have the optimum warehouse layout and cube utilization, reducing the need for the building expansion. Increased store level productivity by organizing product in family groups, eliminating or reducing sorting of product for restocking at the store level (this could reduce warehouse productivity).

How often the warehouse needs to be reslotted depends on seasonality, new product introduction and product life cycle. New warehouse startups it is vital to have products slotted properly for the beginning.

Radix Consulting Alliance utilizes Slot 3D^TM and proprietary methods for slotting. Note: We are not a reseller of Slot 3D to keep ourselves unbiased.

The first New Technology we will discuss is the synchronous reluctance motor; it combines the high performance and energy efficiency of synchronous motors with the cost and maintenance benefits of three-phase AC asynchronous motors. This new motor transfers approximately 93 percent of energy into output and cuts the loss of energy in half. This new technology was announced by Jungheinrich in the US on January 17, 2017 and heavily advertised in PROMAT 2017 (April) with the advertisement of “Run 2 Shifts On 1 Charge – GUARANTEED.”

Depending on the fleet size, the costs associated with water, battery cleaning and additional battery charging stations are eliminated, reducing battery-charging costs by up to 50 percent. The ability to run for two shifts on one battery charge also eliminates the need for an extra battery, saving customers thousands of dollars on battery costs per truck.

The truck models included in this guarantee are:

• EKS 314 High-Level Order Picker – 36 Volt
• ETR 230-335d Pantograph Reach Truck Series – 36 Volt
• EKS 208/308 Mid- to High-Level Order Picker – 36 Volt and 48 Volt
• EKX 514/516/516k Turret Truck – 80 Volt
• EFG 213-220 3-Wheel Electric Pneumatic Forklift – 48 Volt
• EFG 425-S30 4-Wheel Electric Pneumatic Forklift – 80 Volt

The second technology is lithium ion batteries for forklifts. The advantages of a lithium ion batteries are:

Lithium-ion forklift body is approximately two feet shorter than a lead-acid body allowing the forklift to be designed to make tighter turns and allow narrower aisles. Less heat is generated during charging and operation. The lift truck visibility should be improved because of the smaller battery. Lithium-ion batteries weigh less (this could be a disadvantage for counterbalancing loads). They last longer – more than 100% more life according to Kalmar.

Lithium-ion batteries (LiB) charge quicker than lead acid batteries. With a boost charge time of just 30 to 40 minutes , a LiB can absorbs 50% of its capacity. With 80 minutes, a LiB can be fully charged. With boost charging, it is possible to use a LiB equipped lift trucks for up to 24 hours a day, 7 days a week without changing batteries.

LiBs have higher energy efficiency and eliminate the need for a battery change after three shifts. Lithium-ion, and Lithium Iron Phosphate (LiFePO4) is good when it comes to industrial battery use. LiBs last five times longer than lead acid, batteries. Furthermore, LiBs don’t have the voltage reduction that lead acid batteries suffer from. They provide a full charge until exhausted.

They do not have any sulfation issues, or safety issues without gassing so ventilation systems are not necessary in charging areas. LiBs are much safer.

Over the lifetime of the battery of LiB cost should be less taking account of the benefits of no battery changing area needed for 3 shifts of work and narrower aisle spacing, etc. Cost is still a factor relative to lead acid battery technologies; nevertheless, the cost is dropping each year and should be the same or cheaper than lead acid technology by 2020.

Jungheinrich, Kalmar, and Linde have Lithium-ion batteries.