The 5 Pillars of a Master Level Overhead
Material Handling Solution
Volker Schmitz, Ph.D.
President, Schmalz Inc.
PRESENTATION OUTLINE
Speaker Background
Company Overview
Economic Drivers influencing lift assist device use
(5) Factors driving successful implementations & adoptions
(3) case studies highlighting actual results
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SPEAKER BACKGROUND
PROFESSIONAL:
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25 years experience in Manufacturing in the Americas & Europe
17 years experience in Factory Automation
EDUCATION:
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Master’s Degree in Economics from Johns Hopkins University
Harvard Business School – General Manager Program
Ph.D. in Business (Global Contract Pricing)
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COMPANY OVERVIEW
Established:
1910
Ownership:
Privately held - 3rd Generation
Market importance:
World's leading supplier of vacuum technology
for automation and material handling tasks
Sales Growth:
double digits every year (except 2009)
Employees:
800 worldwide, including 13% trainees
Subsidiaries abroad:
15 countries
Intl. Sales partners:
45 countries
Innovation indicators: 180 + International Patents
8% of annual revenues spent on R & D
Distinctions:
ENERGY POSITIVE
ISO 9001:2000
ISO 14001
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(own Wind, Solar, Hydro, wood chips from own forests & bio fuels)
(since 1994)
World of Vacuum Technology
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(4) Business Units using VACUUM
Automation Components
EOAT Robot Tools
Overhead Lift Assist Devices & Cranes
Only company
who is active
in both fields
CNC Machine hold down
clamping
World of Vacuum Technology
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Ignore at your own Peril
Case order picking
of a 70 lbs oversized box
Great Ergonomic Form,
but its still a
Worker Comp Claim
waiting to happen
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REMINDER STATISTICS
2009
55 Million
Working Days Lost
(29% due to MSD’s)
$82 Billion
Cost in Wages and lost Productivity
Over 32 million workers = 25% of US workforce exposed to
body twisting or bending for more than half their time at work
Sources: National Safety Council’s Injury Fact Report (2011 Edition) This figure does not include
medical, administrative, damage to vehicles, fire loss and employers’ uninsured costs. Ref.
Occupational Information Network and Occupational Employment Statistics data; BLS
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COST DRIVERS
• Labor Costs up 500% in last 100 years & trend continues
• 30 Million Worker shortage coming by 2030
• Aging Workforce (2020: 25% of workers will be over 55)
40% in W. Europe
• Warehouse labor turnover among the highest
ANSWER: Need to make jobs less physical
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increase productivity
existing staff retention
accommodate aging staff
expand eligible labor pool to pick from
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WHAT ARE WE TALKING ABOUT:
Overhead Lift Assist Devices
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5 FACTORS for implementation & adoption
Include Operator training
Run off at Factory
Involve Operators (80/20)
Customer talking to Factory
Supplier Warranty & Guarantee
GOAL: 80% adoption rate, 80% risk reduction & 50% productivity gains
Case Study #1:
Effective at risk & cost reduction
Vacuum Tube Lifter used as a Logistics Lift Assist Device
(example: airport baggage ramp handling study)
– 50% + reduction in injury / workers comp claims
after 1 year
– Vacuum Tube Lifter capable of handling 90% + of all
baggage processed
– Practical result: 72% useage by the staff for all
baggage processed
Source: independent study of Munster airport baggage handling staff (2010)
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Percent %
Case Study #1: (cont.)
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Case Study #2:
Higher productivity at low investment cost
Vacuum Tube Lifter used as a Logistics Lift Assist
Device in a large Internet retailer DC facility (overseas)
(3) Systems handling larger sized boxes for outbound shipping
– 55% Productivity
(thru put) increase
– 50% reduction of
personnel (re-assigned)
– inc retention & satiesfaction
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Note: Representative Picture only
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Case Study #3:
Higher Quality Standards
Custom style lifter (with powered rotation)
(2) Systems handling jet engine composite outer housing sections
4 employees
1
Av. 2 damaged housings / M
(cost $ 800,000 total cost/M)
Now $ 0 after 12 months
Better retention & work
environment feedback
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• Thank you for attending this session.
• If you have any questions, input or feedback
• please feel free to contact me.
Dr. Volker Schmitz
President
Schmalz Inc.
5200 Atlantic Ave.
Raleigh, NC 27616
Tel: (919) 713-0880
Cell: (516) 768-5079
volker.schmitz@schmalz.us
www.schmalz.com
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