5 Tips to Keep Your Material Handling System Installation Running Smoothly

When I wrote this originally, disruptions due to the pandemic were rampant. Today life has, in many respects, returned to normal. That includes material handling system installation projects — for which “normal” often means frequent disruptions! Therefore, it seemed the time was right to update this post with some tips for keeping a material handling system installation on track, no matter what obstacles arise.

Tip # 1: Communication among all parties is key.

Regardless of the external factors — geopolitical unrest, economic uncertainty, shipping delays — one of the most essential ways to minimize installation hiccups is communication between suppliers, integrators, and customers.

It’s critical that material handling systems integrators and their customers talk about situations as soon as they arise. More important, it’s essential to develop and offer potential remedies after identifying a threat to the build timeline. Doing so minimizes project disruptions and keeps progress moving forward — even if it isn’t necessarily in alignment with the original schedule.

Frequent formal and informal dialog ensures everyone is on the same page during a material handling system implementation. This applies whether a company is undertaking a greenfield distribution center construction project, or an update or expansion of an existing facility.

Whether the project is on-time, ahead of, or behind schedule, all parties — warehouse automation consultants, contractors, original equipment manufacturers (OEMs), material handling systems integrators — must agree to ongoing, frequent communication. This helps to ensure an equipment installation project’s timeline will run as smoothly as possible while minimizing unpleasant scheduling surprises.

Tip # 2: Buy material handling system components in bulk.

Sometimes a company will plan multiple facility upgrades or installations, either simultaneously or in close sequence. If the plan is for different facilities to utilize common pieces of material handling system equipment from the same supplier, it might make most sense to commission all the equipment at one time.

A bulk order often benefits a manufacturer’s production schedule. For example, an OEM can make several of the same component with one set of tooling before changing over their process to produce the next component.

A bulk buy can also create a stockpile of needed equipment for the customer. This can shorten delivery times or allow material handling systems integrators more flexibility in sourcing components needed for one project should another location’s installation one stall.

Tip # 3: Take inventory of material handling system equipment and parts.

Material handling system installations are complicated, dynamic projects. It’s rare for all the required equipment and components to arrive on time and in the exact installation sequence planned by the integrator. Manufacturing lead times can be negatively impacted by myriad events, such as inclement weather, shipping delays, raw materials sourcing challenges, and so on.

With uncertainty likely, smart material handling systems integrators prioritize having an exacting, precise inventory management process. Best practice is to document each piece of equipment and all components upon receipt.

If a key item is missing (or arrives damaged) and needs to be replaced, it is essential to immediately alert the OEM about the problem. Verify the situation with digital photos of the trailer prior to and after unloading. Then, send those images to the supplier promptly to have the best chance at keeping the project on schedule. Any lag time between discovering the issue and reporting it will likely add more days or weeks to delivery and installation timeframes.

Tip # 4: Adjust the schedule to accommodate available equipment.

The more complex the installation project, the more difficult it is to follow a traditional step-by-step, phased deployment approach. Sometimes the best approach is to install the equipment that has already arrived on-site. Does that mean completing Phase 1 and skipping directly to Phase 3 because the Phase 2 components have yet to be delivered? It might.

Of course, physical gaps around the machinery may need to be left open to accommodate any forklifts (or other means of transporting the equipment), as well as for the addition of the missing parts. Likewise, the components that are installed may need to be left partially unfastened in order to make the detailed adjustments required to fit the different parts together.

However, as long as the engineering drawings are correct and precise, it should be possible to continue to install the elements that have been delivered in order to keep the project on track.

Tip # 5: Provide on-site storage for received material handling system components.

As noted previously, components and equipment required for a new system installation rarely arrive in alignment with the build schedule. Sometimes the building itself is not ready to accept the material handling system components or equipment. Therefore, it’s extremely helpful if a customer can provide their material handling systems integrators with a secure storage area to hold received equipment.

This storage space might be an empty corner of the existing facility. Alternately, it could be a separate warehouse on the same campus (or one located nearby). By providing a safe space on-site to store system parts and components, items can still be delivered and available when needed. This is particularly helpful in a new construction or expansion project.

Let DCS Handle Your Next Material Handling System Installation

In my experience managing customers’ projects with DCS, applying these tips at different deployments has made a critical difference in ensuring that installations stay on schedule.

Want to learn more about working with DCS on your next material handling system installation? Connect with us.

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Author

Brian Niccum, Director of Site Management, briann@designedconveyor.com

With 20+ years in the industrial, baggage and material handling industries in both airports and distribution warehouses, Brian has developed and refined an expertise in electro-mechanical conveyance installations. In his career he has worn several hats, from an apprenticeship level to superintendent, and now proudly wears one as our Director of Site Management. Brian has a love for comedies, sports and more importantly his family and three bulldogs. They thoroughly enjoy Disney trips as well as spending time at the beach and in the Smokey Mountains.