To reduce downtime in servicing new and existing vehicles in automobile, truck and farm equipment parts rooms, maintaining efficient parts availability - from tiny screws to bulky fenders to heavy engine blocks - is critical. But cramped spaces and the continual introduction of new vehicles and parts, along with new part sizes, shapes, weights, quantities and configurations, can make efficient parts management difficult if traditional inflexible storage methods are used.
The City of Philadelphia has found that using a new flexible type of storage system that starts from raw shelving and evolves as its fleet operations do allows its fleet parts managers to create denser, more space and labor-efficient parts storage capacity as business, budget or storage needs change.
TRADITIONAL STORAGE
While traditional modular drawer cabinets on casters are fine for technicians to roll around the shop, their main drawback for parts storage is that they are essentially unchangeable steel boxes, unable to efficiently accommodate changing part sizes, shapes, weights, quantities or configurations, says Bruce Donatelli, a supervisor with the City of Philadelphia's Office of Fleet Management.
Once the size of the drawers and box frame is set, modular drawer cabinets have virtually no future adaptability, as different size drawers are not typically swapped out to better meet changing part size or shape, space usually isn't used effectively, he explains. For instance, storing washer-sized parts in 6-inch drawers wastes a large amount of storage space.
Though traditional storage shelves offer more space than modular drawer cabinets, a tremendous amount of storage space can also be wasted if, for instance, 3-inch-high parts are stored on 24-inch-high shelves, Donatelli adds. Because moving a shelf to create denser storage space can often require removing and reassembling 10 or more nuts and bolts, this is practically never done on a large scale.
"When parts storage capacity lags behind the need, clutter results with parts too often stored on the floor or on top of cabinets and stacked in boxes," he says. "Productivity is lowered if parts are not quick and easy to store and retrieve."
STORAGE PRODUCTIVITY
Manufacturers make a lot of changes to part design and shape from year-to-year, observes Donatelli. "To improve productivity, we sought to consolidate most of our parts storage from bulky, traditional shelves on our third floor down to more flexible, space-efficient shelves in our first floor service bays where the work actually gets done."
The City of Philadelphia's Office of Fleet Management turned to a flexible modular storage system called V-Grip by Equipto, a supplier of industrial storage designs and solutions (www.equipto.com). Equipto is a business of Consolidated Storage Companies, a leader in storage and shelving systems.
What makes the V-Grip storage system unique is that it starts as raw shelving and allows parts managers to adapt and create denser and denser storage capacity as business, budget or storage needs change, says Robert Ammerman, CEO of Consolidated Storage Companies. The modular storage system is more flexible than modular drawer cabinets or traditional shelves because it is designed so shelves, drawers and other accessories can be interchanged in the shelf cavity.
Since each shelf, drawer or accessory is individually mounted to upright posts using a proprietary bracket system, they are individually adjustable and can be added at any time without disassembly of the unit, he points out.
The V-Grip system begins with heavy duty uprights, and top, bottom, back and side panels. Shelves with up to 400-pound capacity can be added and adjusted at 3-inch increments for storage of bulk items, and items of different sizes.
For more efficient storage of small- to medium-sized parts, drawers in 3-inch increments can be added, along with drawer or shelf dividers to keep small parts from mixing, says Ammerman. For more security along with visibility, locking and see-through doors in various combinations can be added.
"The option to add or adjust shelves, drawers or other accessories as needed should help us maximize storage density where it is needed most, next to the service bays, even if part sizes or configurations change," Donatelli says.
VERTICAL STORAGE
While multiple rows of adjustable shelving accommodated the bulbs, fuses, hoses, filters, brake pads and other small- to mid-sized automotive items that Donatelli wanted to house near the first floor service bays, he also needed more space to store larger items. So, he went up.
"With the V-Grip storage system, we at least doubled our storage in a limited space," he says. "We added vertical storage with a deckover mezzanine above our shelves with stair access. This gave us the room we needed for bulky items such as doors, hoods, fenders and body panels."
Adding vertical storage with a freestanding or deckover mezzanine is straightforward, if adequate vertical space is available. No bracing is needed. The storage just needs to be reconfigured to put a second floor right on top of the shelving.
MOBILE ISLE SYSTEM
For shop parts facilities that lack enough vertical space to add mezzanine storage above shelving, but still need to maximize their storage density, another option is to put existing shelves on carriages and platforms to create a mobile aisle system, says Ammerman.
Mobile aisle systems move the shelves toward each other to eliminate unnecessary aisle space, he says. Reducing the number of access aisles can save as much as 50 percent of floor space, or double existing storage capacity.
When needed, a mechanical assist drive system requires only 1 pound of effort to move 10,000 pounds of mobile aisle load on a system such as Equipto's V-Grip.
STORAGE SECURITY
Another advantage of mobile aisle systems is how easily they provide additional layers of storage security for high value items, says Donatelli. To lock the entire system down, just roll the mobile aisles together and lock the end carriage.
Since such a lockdown can be accomplished with a single key, the system is quick to lockdown and quick to get back in use for higher productivity on the shop floor, Ammerman adds. An additional layer of security can also be added with optional lockable doors in the shelving.
"Maximizing our storage space allowed us to consolidate most of our upstairs parts operation downstairs in a much smaller space," says Donatelli.
"Now, our technicians have fast part access right in the service bay. They no longer have to travel three floors up and three floors down to get a part.
"We're more productive, and it won't be long before we achieve our ROI."
City fleet saves time, money with fluid management system
Always looking for ways to increase productivity, Bill Burns, fleet operations manager for the City of Columbus, OH, began researching the advantages of implementing a fluid management system at the city's new fleet maintenance facility. He recognized that fluid control was a key to improving efficiency and creating a smooth flow throughout the garage.
After meeting with representatives from several suppliers, Burns chose the Lincoln LFC 5000 fluid management system. Among his reasons for the decision is that the system:
- Confirms valid and open repair orders on the facility's AssetWorks management system.
- Captures dispense events instantly and automatically to eliminate manual entering and errors.
- Accounting functions are completed accurately on the repair order and invoice, recording inventory depletion and eliminating lost billings.
- Simultaneously controls and monitors up to 32 fluids and 300 dispensing locations and creates reports by product, user, customer or location.
"The installation of Lincoln's automated fluid management system has dramatically improved our fleet technicians' efficiency," says Burns. "Our technicians no longer have to travel to and from the parts counter to request and receive vehicle fluids.
"When you have a large repair facility and 70 technicians, every step counts."
BETTER EFFICIENCY
Burns adds that all fluid requests/dispenses are made in the technician's bay via the Lincoln system, and each transaction is completed electronically and charged to the work order.
"The parts department employees automatically gain the efficiency of not having to manually or electronically charge out fluids," he says. "By setting up our new facility with the complete Lincoln system - including pumps, reels and meters, our facility not only saves fleet employees' time, it also has enabled us to lower our fluid purchase cost by buying in bulk."
According to Burns, buying lubricants in bulk dramatically lowers the purchase price for the city when compared to buying in refinery drums or smaller containers. The oil company also is able to more easily keep the tanks at a proper level through bulk deliveries.
"The Lincoln Tank Monitor system allows selected individuals at the Columbus facility to confirm inventory levels in real time," he says. "This enables them to check the levels before and after a bulk delivery, verifying the actual amount the driver delivered.
"The use of bulk lubricants, together with the Lincoln pump/reel delivery system, allows our technicians to handle all lubricant needs from their bays, increasing productivity."
Give technicians a lift toward greater productivity
Other than fuel, labor is often a fleet's largest equipment and maintenance expense. Increasing technician productivity, therefore, can significantly reduce operating costs.
"Most modern maintenance facilities have invested in a wide range of labor-saving equipment and procedures," says Doug Spiller, heavy duty product manager for Rotary Lifts, a world leader in hydraulic light duty/heavy duty vehicle lifts and special tools (www.rotarylift.com). "Yet, many of those facilities still rely on floor jacks, creepers or pits to position their technicians under a truck for service.
"Vehicle lifts are one of the last remaining upgrades that can significantly increase technician productivity."
WORKING AREA
Vehicle lifts are designed to safely raise vehicles to a comfortable working height and keep them, improving productivity by making it easier for technicians to reach every component of a vehicle, with plenty of working room, Spiller says. This provides technicians with complete access to a vehicle's undercarriage, enabling them to use tools and equipment to safely remove and replace heavy components without manual lifting.
Along with improving visibility and ergonomics, lifts also make it easy to perform services that require the wheels to be free or the suspension to be unloaded, such as for lubrication, brake, wheel, transmission and suspension work, he adds.
Rather than having to lie on their back a few inches from a vehicle's undercarriage, twisting around to try to reach tools, with lifts, technicians can stand up comfortably, within easy reach of tools and equipment, explains Spiller. "They are more comfortable, efficient and able to complete more work in less time."
Like any product, not all lifts are created equal, he notes. Lifts that take less time to set up, raise and lower a vehicle will improve productivity more than slower, cumbersome equipment.
How to protect the investment in tool storage units
By David A. Kolman, Editor
Keeping tools clean is paramount to maintaining a professional and productive working environment. Taking care of tools and cleaning them often keeps them working at their peak efficiency.
It is also important to have well-organized and clean surroundings in a shop, and to make sure investment lasts as long as possible.
Often, little thought is given to cleaning tool storage units - an important business asset, say officials at Snap-on, a leading global innovator, manufacturer and marketer of tools, equipment, diagnostics, repair information and systems solutions (www.snapon.com).
Like a vehicle, it is important to clean and wax tool storage units on a regular basis to protect its finish, they advise.
What is just as important is using cleaning products, such as cleaners, waxes, polishes and microfiber clothes, which are specifically designed for tool storage units, note the officials. Such products not only protect the tool storage unit, but help to bring back that brand-new shine.
CLEANING STEPS
When cleaning the tool storage unit, Snap-on officials recommend the following steps.
1. Choose a cleaner/degreaser that will remove grease, dirt, oil and fingerprints without damaging the surface of the unit. Make sure the cleaner is water-based and body shop safe.
2. After the tool storage unit has been thoroughly cleaned, wax it to help bring back the shine. By choosing the proper wax, the finish on the tool storage unit will resist water spots, fingerprints and dust.
Use a liquid polish to safely clean, polish and protect the stainless steel and anodized aluminum, but make sure the wax and polish are also water-based and body shop safe.
3. Select a microfiber cloth that doesn't collect lint and can be used wet or dry. A machine washable cloth is also preferred, as it is more durable and provides for a longer life.
Cleaning and maintaining tool storage units should be on the "to do" list of every shop owner or service technician, say Snap-on officials. "Not only will taking care of tool storage units extend the life of your investment, it will also show that you take pride in your business and the image you project to your customers."
How vehicle lifts relate to shop efficiency
Shop productivity increases can be achieved by choosing the appropriate vehicle lift. Having the proper, most efficient lift for the intended application equates to helping a fleet have its vehicles spend more time on the street rather than in the shop.
"A higher percentage of usability of a fleet keeps more vehicles available, in use or making money for the company," says Steve Perlstein, sales and marketing manager for Mohawk Lifts, a leader in lift technology (www.mohawklifts.com).
Regardless of what type lift a shop uses, there are increases in efficiencies to be had, he says. One specific example is the lifting speed of a mobile column lift.
MOBILE COLUMN LIFTS
"There are two types of mobile lifts: screw drive or hydraulic drive," explains Perlstein. "A screw drive takes two to three minutes to reach full height and to drop down, while some hydraulic mobile lifts take just 60 seconds fort each operation.
"If a technician was to raise and lower a screw-driven lift four times a day, the efficiency difference is 20 minutes a day. Over a 200-day work year, the technician will have spent 26 hours raising and lowering a hydraulic mobile lift versus 80 hours operating a screw-drive mobile lift.
"If your internal overhead shop rate is $50 per hour, the efficiency difference in these two types of mobile lifts is $2,700 a year, every year, year after year."
SIDE-BY-SIDE LIFTS
Two post side-by-side lifts, available in capacities from 7,000 to 30,000 pounds, are the most popular lift used, according to Perlstein. These lifts take up the least amount of shop space, give technicians the most under-vehicle access and leave tires hanging for wheel service.
If there is a single drawback, he notes, "it's always the four to five minutes it takes to position the swing arms under the vehicle lifting points. Yet, there are some lifts that offer the convenience and access of a two post lift without the need to position all four swing arms.
"Essentially these optional accessories make the two post lift into an instant 'on' and instant 'up.'"
FASTEST LIFT
The fastest lift to use is a drive-on lift, Perlstein says. Drive-on lifts range from the more popular four post type to parallelogram and scissor style lifts.
The speed of using drive-on lift, as the name infers, is that vehicles can be simply driven on the lift," he says.