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f+h Intralogistics 3/2015

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f+h Intralogistics 3/2015

INDUSTRIAL TRUCKS 100

INDUSTRIAL TRUCKS 100 percent readiness The Brazilian-based manufacturer Fiat Powertrains gets the job done using new forklifts from Jungheinrich. The client signed a full-service rental agreement with Jungheinrich, ensuring that Fiat Powertrain can concentrate on its core competencies in its day-to-day operations. The dispatching station at the Fiat Powertrain engine plant – one of the biggest engine plants on the South American continent – is a busy place. There, about 750 freshly produced 1.6 and 1.8 litre engines are loaded and shipped out in mint condition daily. “This means that a complete engine rolls off the line every 41 seconds,” explains Celio Berton, Material Handling Leader at Fiat Powertrain in the southern Brazilian city of Curitiba – about a one-hour flight from São Paolo. Efficient structures are a key factor in ensuring the plant’s constant high level of performance. Located just outside the Brazilian metropolis of Curitiba, the engine plant has been operated by Fiat Powertrain since 2008. The engines manufactured here are delivered to two locations in South America’s biggest nation: Pernambuco in the northwest and Minas Gerais in the centre of the country. From Minas Gerais the engines are also shipped to other countries like Argentina or Italy. The parts used to manufacture the engines come primarily from Brazil, at a rate of 93 percent, with the other seven percent being imported. High throughput, low energy consumption The pallets arriving at the Campo Largo engine plant are unloaded and stored provisionally in the incoming goods area using a variety of vehicles, including electric counterbalanced forklifts manufactured at the Jungheinrich plant in Moosburg near Munich, Germany. These EFG 425 vehicles can handle payloads of up to 2,500 kg, making them predestined for fast, energy-saving loading and offloading operations that involve lorries. “This is essentially due to our pure energy engineering concept,” explains Sarah Oliveira, Key Account Manager at Jungheinrich Lift Truck-Comércio de Empilhadeiras Ltda, “a concept which guarantees an high throughput rate, while simultaneously ensuring that only a small amount of energy is consumed. These advantages are based on the use of the latest 18 f+h Intralogistics 3/2015

INDUSTRIAL TRUCKS A. C. three-phase technology in combination with a control system which rationally apportions the amount of energy fed to the various hydraulic modules and motors.” After the lorry is offloaded the goods are checked and cleared for a slot in the production storage area. “Until recently our storage capacity here was limited to 1,420 pallets,” relates Berton. “But after a sophisticated expansion of the existing building we are now able to store a total of 2,480 pallets” – part of the efficient structures which guarantee the facility’s smooth performance. Full-service guarantee Another piece in the “efficiency puzzle” consists of supplying engine production with the required parts. “The main factor here consists of particularly short response times to ensure the most efficient production operations possible,” remarks Berton. While Fiat Powertrain uses a number of tried-and-tested vehicles to store its incoming goods – among them trucks with a few years under their belt – it relies exclusively on new vehicles for the delivery of production parts to the shop floor. The plant’s “upto-date fleet”, as Berton calls it, was put out for tender and the competitive bids were judged according to several different criteria. “The decisive factor was the cost-benefit ratio over the entire lifecycle”, explains Berton. The German-based Jungheinrich group, with a nearly 15-year-old subsidiary in Brazil which employs some 130 staff members, ultimately got the nod – even though Berton confesses to never having heard of the company previously. The rental agreement Fiat Powertrains concluded with Jungheinrich extends over a period of 36 months. The special feature of Jungheinrich rental agreements: Apart from vehicle financing, they also contain an assurance of 100 percent readiness, since there is always a full-service clause. According to Oliviera, this means the customer can concentrate on his core business and pass the responsibility for industrial truck availability over to Jungheinrich. Berton concurs: “Indeed, we enjoy full readiness without any risk to us.” Outstanding working conditions, high performance When an order from the production area is received, a brand new ETV 110/112 reach truck removes the required item from storage. These stackers represent compact and highly manoeuvrable vehicles with aboveaverage performance rates. “Using these Jungheinrich trucks we get up to 20 percent higher efficiency compared to our core fleet,” comments Berton, adding that the company’s drivers were “thrilled with these stackers”. This may have to do with the generous amount of space in the driver’s cab. “Despite the small size of the forklift, the driver’s place in the ETV 110/112 provides the operator with outstanding working conditions,” says Oliviera. In her estimation, a working space where a person feels good is another reason for the high performance levels achieved in everyday operations. As soon as all the required parts are removed from storage, they are loaded onto special trailers and transported to the production area using EZS 130 tow tractors – a particularly “slender” make of Jungheinrich tow tractor. “These trucks are only 600 millimetres wide, but can tow loads of up to 3,000 kilograms,” explains Oliviera. “This makes them the ideal type of truck for especially narrow areas, which is often the case in production.” Additional features guarantee convenient, safe operation: The Speed Control impulse electronic management system for example ensures that the speed set by the operator on the drive console is maintained in any driving situation. And the Curve Control module allows the driver to keep the tow tractor under control even when rounding a curve: Similar to the electronic stability program (ESP) for cars, Curve Control automatically reduces vehicle speed when cornering, thus ensuring a substantial plus in safety. Safety which is crucial if 750 Fiat Powertrain engines are going to leave the plant in mint condition daily or if one is going to roll off the line every 41 seconds – all a matter of perspective. Photos: Jungheinrich www.jungheinrich.com About Jungheinrich Jungheinrich is one of the world’s leading companies in the industrial truck, warehousing and material flow engineering sectors. As a manufacturing service and solution provider in the field of intralogistics, the company, based in Hamburg, Germany, supports its customers with a comprehensive product range that includes forklift trucks, shelving systems, services and consulting. The Jungheinrich share is traded on all German stock exchanges. MULTIMEDIA CONTENT External video: Learn more about the achievement spectrum of the enterprise. / Perfect Welding / Solar Energy / Perfect Charging MaxiMuM battery service life. MaxiMuM energy efficiency. / Battery chargers with the new ri-charging process: www.fronius.com/ri-charge Fronius-Englisch.indd 1 13.05.2015 16:06:50 f+h Intralogistics 3/2015 19

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