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| Portmeirion’s warehouse was streamlined using tightly arranged rows of Mecalux pallet rack |
Portmeirion USA
HIGH-DENSITY PICK AND BULK STORAGE
CONVEYORS
In 2007, Portmeirion® USA – the lone U.S. distribution center for popular British dinnerware manufacturer Portmeirion – moved its Connecticut warehouse from a 35,000-square-foot facility in Naugatuck to a 76,000-square-foot one in Waterbury, and they teamed with Maybury to make the time-sensitive transition as cost effective as possible.
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| Maybury created more than 1400 pallet positions within just 8500 square feet of space. (CLICK
PHOTO TO ENLARGE) |
Hardigg Industries
DOUBLE-DEEP STORAGE RACK
MODULAR OFFICE
For more than 20 years, Maybury account manager Bill Sieber has worked with Hardigg Industries, Inc. of South Deerfield, Massachusetts, providing material handling solutions that matched the company’s growth. As free floor space at Hardigg’s facility has become more and more sparse, they have relied on Maybury for solutions to maximize their storage and office space. Recently, when Hardigg’s rapid growth in injection-molded case business created a need to better optimize the floor space in their finished goods warehouse, they turned to Maybury. In addition to coming up with a plan to install a double-deep Interlake pallet rack system in this area, Maybury developed a plan for a Starrco Modular Office, which would allow Hardigg to make room for support staff for a new internal custom case assembly operation directly on-site in their receiving warehouse.
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| 36 Crown stockpickers and 1.2 million pounds of rack help keep Bob's warehouse running smoothly. (CLICK
PHOTO TO ENLARGE) |
Bob's Discount Furniture
DOUBLE-DEEP STORAGE RACK
STOCKPICKERS
In Norwich, Connecticut, Bob's Discount Furniture maintains a large storage and distribution center for furniture and bedding, from which approximately 1 million pieces were shipped in 2005. They receive solid containers filled with multiple units of the same product, then store the contents in this warehouse. To ensure the continued growth of the company and provide job security for their 1,500 employees, Bob's Discount Furniture had been wanting to expand their storage capacity and increase the volume of product handled. To that end, they have just completed a new 272,000-square-foot warehouse addition. One of the goals of the addition was to move all inventory under one roof. This would reduce furniture handling (reducing, in turn, damage to the furniture); decrease manpower required; and allow for higher profits. Additionally, Bob's Discount Furniture wanted to improve storage safety and provide a safer environment for their workers.
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| Serco state-of-the-art dock equipment provides lift truck operators with a solid, secure platform for loading trailers with OMG product. (CLICK
PHOTO TO ENLARGE) |
OMG, Inc.
ADJUSTABLE PALLET RACK
DOCK EQUIPMENT
OMG, Inc. of Agawam, Massachusetts, is a manufacturer and supplier of fasteners and fastening systems for the construction industry. In order to double their storage capacity, they decided to build an entirely new distribution center. This would be accomplished with a 40-foot-high ceiling, rather than with a larger building footprint. Maybury Material Handling was selected early-on in the project to supply the pallet rack. Maybury's input included identifying floor loads and necessary reinforcements, based on rack weight, with consideration for the implications of rack and product placement on worker safety. Plans for OMG's state-of-the art distribution center included 12 docks with shelters, levelers and truck restraints. Keeping in mind OMG's focus on safety, Maybury was confident that Serco dock equipment would be an excellent choice for the new facility.
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| State-of-the-art
order picking is made possible by this new two-level
pick module from Maybury. (CLICK
PHOTO TO ENLARGE) |
J.
Polep Distribution Services
ORDER PICKING SYSTEMS
New
products, more customers, and the need for faster
movement had exceeded the capacity of J. Polep Distribution
Services' existing order picking system. Maybury
Material Handling was asked to look at the existing
system and provide insight as to what could be done
to structure a more efficient facility. Maybury designed
a two-level pick module utilizing Interlake Material
Handling's rack,
conveyors, and
carton and pallet flow units, integrated with a Maybury
mezzanine, and Quantum Conveyor's automated induction
and sortation systems. With its new Maybury-designed
and -installed system, J. Polep Distribution Services
has been able to increase the volume of product movement
through the facility, in terms of both number of items
and number of picks per item.
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| A
50' x 100' mezzanine from Maybury helped Play-Doh
increase productivity at their new facility. (CLICK
PHOTO TO ENLARGE) |
Hasbro/Play-Doh
MEZZANINES
When
Hasbro decided to relocate their Play-Doh manufacturing
facility, they chose Maybury to assist them with the
restructuring of their Production Department.
The
relocation entailed moving all of the hardware for
Play-Doh processing into a smaller area, so design
efficiency was key. Maybury installed a 50' x 100'
mezzanine with
a 25' clear span between the columns. This
5100 sq. ft. mezzanine holds 36 bins of empty containers
which are pulled on demand for filling. An auxiliary
mezzanine measuring 2100 sq. ft. was installed for
storage of mixing equipment. With this setup, Hasbro
is able to fill 12,500 6 oz. cans per hour. Working
two 12 hour shifts, they produce 300,000 6 oz. cans
per day!
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| Maybury
installed 29 Serco Ultra Seals at Lego's loading
area in Enfield, CT. (CLICK PHOTO
TO ENLARGE) |
Lego
Systems, Inc.
LOADING DOCKS
When
Lego decided to expand their loading docks, they came
to Maybury for our expertise in material handling
safety and productivity. To ensure the safety of Lego
employees, we recommended the Dock Guard™ Barrier
Lip option on Serco's HFC hydraulic levelers. In addition
to installing twenty-seven hydraulic levelers with
the barrier lip, Lego also had Maybury install twenty-nine
of Serco's SL2060 Safety-Loc™ truck restraints.
The Serco dock equipment
installed by Maybury helped Lego to increase productivity
and efficiency, while maintaining strict standards
for employee safety.
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| Maybury
replaced American Saw's traditional incline/decline
conveyor system with this vertical one. (CLICK
PHOTO TO ENLARGE) |
American
Saw & Manufacturing Company
CONVEYOR SYSTEMS
ORDER FULFILLMENT
When
American Saw & Manufacturing Company, a world-wide
leader in the manufacture of saw blades, needed more
floor space in two of their departments, they contacted
Maybury. Maybury
replaced a system of typical incline/decline conveyors
with a vertical system that integrated directly with
their main conveyor. The new system freed up floor
space, cleared blocked aisles and speeded up product
processing.
In
addition to a lack of floor space in that department,
American Saw's Literature Department was in need of
more storage space. A newly installed integrated storage,
conveyor and packing system has improved the workings
of this department. Through the use of the proper
shelving, conveyor,
ergonomic lift load balancers and a walkie lift
truck, Maybury, in conjunction with the staff
of American Saw, was able to design a safer, more
efficient literature order fulfillment system to meet
customers' needs.
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| This
rack system is just one of a wide range of products
used to put together the Mashantucket Pequots'
massive warehouse storage system. (CLICK
PHOTO TO ENLARGE) |
Foxwoods
Casino
WAREHOUSE STORAGE SYSTEMS
When
the Mashantucket Pequot Tribal Nation needed a massive
warehouse storage system for records, artifacts, supplies
and retail goods related to Foxwoods Casino, Maybury's
plan came out on top. Maybury utilized the products
of many of its major vendors for this project. Interlake
rack, Nelson steel
decking, Maybury mezzanines,
a Starrco modular office,
Wirecrafters fencing, Crown lift
trucks, Pflow Industries vertical reciprocating
conveyors and a
Railex garment handling system are all part of the
new facility. The system now stores and supplies just
about everything it takes to keep the world's largest
casino running smoothly.
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| Maybury
designed a dual conveyor system for Friendly.
(CLICK PHOTO TO ENLARGE) |
Friendly
Ice Cream Corporation
CONVEYOR SYSTEMS
Friendly
Ice Cream Corporation of Wilbraham, MA, came to Maybury
with the need for a system to convey and control several
types of frozen products. The system would convey
products from two separate production locations to
one of two automated palletizers. The
extremely limited space in which the system was installed,
as well as the manufacturing process involved, dictated
that Maybury design and fabricate several customized
devices. The very cold environment of this installation
also presented Maybury with special challenges. The
system is now in full operation, providing highly
efficient conveying of all types of frozen treats,
from festive holiday rolls to cartons of "good
old vanilla."
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