Forklift fleet moves auto parts in high gear

Discount Auto Parts gets big productivity gains from reach trucks and walkie rider trucks that handle three pallets at a time.

Modern Materials Handling - October 2, 2002

Rapidly growing Discount Auto Parts handles over 50,000 different automotive items through some 700 sites. To keep pace with growth, the company added a 400,000 square foot, cutting-edge distribution center in Gallman, Miss.

High productivity from the fleet of lift trucks is vital at Gallman. During a normal week, some 100 licensed operators work three shifts, five days a week. They receive, ship, and process 650 pallet loads while averaging 350,000 picks. First shift utilizes the entire 44-truck fleet. Second and third shifts use about 50 percent of the fleet, primarily putting away and re-stocking parts.

One brand of lift trucks was chosen for this distribution center, explains Steve Valenz, manager of distribution automation. 'After extensive demonstrations with three other manufacturers, we looked to one company to provide the productivity and safety answers we were looking for. And it delivered.'

The analysis included use of demo equipment and comparisons of productivity, safety, and ergonomics. 'We also compared several maintenance aspects in regards to accessibility to truck components and ease of troubleshooting,' says Valenz. 'Productivity, ergonomics, safety features, and maintenance put this company well above the other three competitors.'

Initially, Valenz downplayed using reach trucks because drivers have the option to sit or lean while operating. 'I thought sitting can sometimes create a too comfortable position and have a negative impact on productivity,' he recalls.

But the lift truck dealer won him over by having operators demonstrate a reach truck. 'Our findings quickly revealed that operators liked the truck's performance and the comfort,' he says.

Studies also quickly revealed this decision made sense-and saved lots of cents, which converted into sizable dollar savings. Valenz projects operators are achieving a 24 percent productivity increase from four reach trucks.

Furthermore, drivers like these reach trucks. Veteran operator Al Hannon says, 'the truck has great speed yet is very safe to operate.' Eddie Jones likes its ability to maneuver. He's adept at using the steering tiller and multi-task control to perform his job. He also believes his productivity is enhanced with the truck. 'Towards the end of a long shift, it really helps to be able to sit down,' he says.

More productivity gains were achieved through walkie rider pallet trucks, especially units that handle three pallets at a time, not just two. These triple pallet trucks have proven to be workhorses, handling loads up to 8,000 pounds and allowing a 50 percent productivity increase-three pallets can be transported across the distribution center instead of just two. Triple pallet trucks also increase the speed of loading outbound trucks by only requiring eight trips to load a full trailer.

'Some of the other manufacturers do not even offer these triple lifts. Again, it's another example of the many reasons we choose this equipment over its competitors,' says Valenz.