Tuggers Material Handling
By Sara Pearson Specter ·
Manufacturing facilities are continuously looking to get lean while meeting the increasing expectations of consumers for mass customization of products. Couple those challenges with an aging workforce and—in many parts of the country—a difficulty attracting and retaining qualified workers, the resulting solution for some companies has been the implementation of a designed lean material flow system.
The key to those systems, according to Larry Tyler, vice president of sales and marketing for K-Tec/Kinetic Technologies, is the reduction of a facility’s current fleet of fork trucks by replacing some of them with tugger and cart systems. “A fork truck is a vital component of a complete materials handling system: It’s not the bad guy, ” Tyler says. “It’s just one way to move materials, and as long as 15 years ago, fork trucks were the most efficient way.”
Today, however, tuggers and carts have evolved to the point where they can be flexibly engineered to support some, or all, of a facility’s handling needs. Both manned and unmanned tuggers work with powered and non-powered carts in a virtually limitless range of configurations. Their features and flexibility allow these systems to address production complexities previously only handled by fork trucks. In turn, fork trucks can be limited to the perimeter of a facility—for shipping and receiving, and for inventory placement into and out of racks—to increase the safety of personnel in the area.
In manufacturing, tugger and cart systems replace one-load-at-a-time deliveries by fork trucks to the production floor by acting as trains, or a linked series of multiple carts, carrying multiple loads in one trip. The carts themselves may be loaded by a fork truck, but a tugger handles the deliveries. Unlike a fork truck, automatic guided vehicle (AGV) style tugs travel along a pre-determined route and at a limited speed, while manned-style driven tug operators have greater visibility because the loads trail behind instead of riding on elevated forks in front of the driver.
Changing roles of carts
Delivering smaller lots more frequently in kitted and sequenced cart orders is an engineered response to the complexity of mass customization. Building multiple product lines on the same production floor or offering a selection of options to customize a standard product, require the flexibility that carts can provide, Tyler explains. The carts have evolved into specialized tools used in engineered processes to move materials as efficiently as possible.
“For parts deliveries to a production line, horizontal space is at a premium, ” Tyler says. “Production engineers can be reluctant to build fixed solutions, such as a conveyor, because the process may need to change going forward. That’s why the flexibility of cart-based solutions can make more sense from a return-on-investment perspective.”
Further, “I think of conveyor as being ideal for situations where you’re moving more than 60 loads per hour, ” says Chuck Russell, vice president of sales at Transbotics. “If you have a really long run, a conveyor breaks up the plant, crosses aisles, requires power—it can be really expensive. But to make a long run of anything more than 300 feet, or if you have to snake in and out of existing facility structures, then a tugger might be a better choice.”
Most tuggers can handle a total maximum capacity of 10, 000 pounds, including the load and the carts, when hauling across a flat surface, says Russell. While, in theory, the number of carts pulled behind is limitless, the actual number of carts that can be towed is limited by the hauling capacity of the tugger. If you require the tug to travel up or down an incline, across a rough surface, or outside from one facility to another, a whole host of additional complicating factors come into play.
“It’s very important to consider the stopping distance required by a tugger pulling a train of carts, particularly down a ramp. Traveling down an incline produces more kinetic energy, and the tugger’s brake system has to be able to handle it, ” Russell says.
Another limitation to the number of carts a tugger can pull is aisle width. Whenever a train of carts pulled by a tugger has to make a turn, the more carts in the train, the more clearance the system will need. That’s because of cart drift.
“If you put two carts in a train, they’ll follow the tugger on the same path, ” explains Russell. “If you add a third, the last cart has a slightly different turning radius; the more carts you add, the wider your aisles will need to be.”Where to answer instagram questions? How many grow lights do i need? How many important side ops in mgs5? Where to grow mint? Where to find object selection tool in photoshop? How many research universities in the us? What create wind? When engineering and administrative controls? How often does tiktok algorithm change? Where to machine rotors near me? Why activities are important for dementia? How many degree today? Where to get industrial piercing? Why user not found in instagram? How much internet does streaming use? Where in the industrial field is radioactivity used? Why skills are important for job? How skills dbt? Summary when breath becomes air? Who classification of tumours of haematopoietic and lymphoid tissues? Why recruiter is important? Whose does this belong to? What is the best type of maintenance? Which marketing certification is best? How much generator do i need? How summary book? When theory becomes fact? Why diagrams are used? Where to construct architect body? Where to learn math online? When degree colleges start in karnataka 2022? Which blogging platform is best for making money? Which developer is best for gray hair? When engineering colleges will open? Who activities in india? Where research begins mullaney? What create gravity? When is classification important? When theory test will open? How long theory test last? Which marketing career is right for me? What marketing jobs are there? The industrial revolution began in? Why developer option is hidden on firestick? Who whom examples? Where degree of the polynomial? Which intelligence is strongest for an architect and artist? Who maintenance manual for laboratory equipment? How architect make money? Skills when reading? Whose meaning in telugu? Where's summary tab on itunes? How engineering firms practise sustainability? Why blogging nowadays is trending to the students? How much research experience for md phd? Where object not like powershell? Where grow pineapple? Where i'm from poem summary? Which marketing course is best? What examples develop the ornery nature? Why summary writing is important? Where example questions? Where to find engineering research kenshi? Who's theory was natural selection? How much create human? Where do interviews take place? When examples sentences? How much degree celsius today in my location? How many skills on a resume? How much architect charge in india? Where industrial revolution began? Why examples are important? What degree is an approach wedge? How far an object be from the pole of a concave mirror? Whose career inspires you and why? Who leadership and management framework? Workshop how to do? Were machine guns banned? Why activities are important for dementia? Who influence you to choose this course? Whom sentence examples questions? How many challenge all stars are there? Whose generation is known as bani israel? Whom subject or object? How much activity a day? Whom use? Where create date sql? How to develop knowledge and skills? How much architect make? How many maintenance planners do i need? Where industrial revolution started? Who summary sheet? How far plant tomatoes apart? Where to find developer tab in excel? Which machine is best for body contouring? Why architects los angeles? Who created school? What career is right for me? How many theory of play are there? Home improvement where to watch? How much grow light for plants? When dev uthani gyaras 2022?