In weighing up the efficacy of loading bay operations, four key criteria usually dominate: 1) their ability to allow maximum efficiency in goods transfer between vehicles and loading bays, 2) the health and safety of the operation, 3) energy savings that could deliver remarkably short payback periods, 4) their future-proof adaptability. Achieving all these on a permanent basis also depends heavily on a fifth issue: a consistently first rate after-sales service.
It is a complex scenario that should not be left to inexperienced equipment suppliers for therein lurk hidden costs, like the supplier’s failure to assess his client’s loading bay operations adequately or who use unapproved budget components. In one case, for example, a national distributor bought dock levellers from a local supplier, based on a very low quote but the supplier failed to take into account the weight of fully laden forklifts during the specification process. Consequently, the dock leveller began to fail within one week. This highlights the need to be wary of low quotes and use only members of well-respected associations like the Association of Loading and Elevating Equipment Manufacturers (ALEM).
When considering a new build warehouse it also makes sense to deal directly with the loading bay equipment supplier rather than leave it all to an architect. This is because ALEM members will know much more than architects about the critical problems that could hamper the smooth interaction between vehicles and docks. Although better than they were, architects may still design a warehouse loading bay poorly, which causes high remedial costs.
Leading loading bay equipment suppliers may also be relied on for showing prospective buyers sites they have completed for large operators. This should be an essential ingredient in any buying exercise where the investment is high. Vital facts can be learned on equipment performance reliability and the after sales service. The latter is often neglected, leading to serious downtime. Lack of a regular service regime is a false economy.
Using accredited suppliers as safety advisers makes sense. If there is early consultation, safety can be designed in from the outset, saving money in the long-term and ensuring that efficiency and safety are jointly considered. The fact is, the loading bay is usually the most dangerous part of any warehouse, despite the best efforts of suppliers to provide new safety devices that, for example, prevent premature lorry departure from the dock. The most difficult and least predictable element is the human being and so that means adequate training is paramount. Employers should speak regularly with employees to encourage them to be involved in communicating any problems and any ideas on how matters could be improved.
One issue that highlights both safety and future proofing is the problem of numerous flat floor sites where there are no docks. The usual approach to this is to use a combination of pallet trucks and forklifts to interface with lorry loads but that means the operators struggle, which raises the safety risks. One solution put forward by Transdek is its vehicle-o-ground loading system, based on hydraulic lifts. It is not only easier on the operatives but also copes with double-deck lorries, now gaining wide acceptance and which dock levellers cannot handle.
Suppliers can be helpful over the energy-saving potential of their doors, particularly the fast acting roller type. Some will provide an online calculator with expected payback periods. Nowhere is the energy issue more critical than in cold stores, where the energy bills can typically account for between 25 and 30% of total store operating costs. It would not be exaggerating to say that reliable doors are the key ingredient in maintaining the integrity of the freezer environment. Sliding insulated store doors, whether manual or electrically operated, for high traffic use should be avoided as these can lead to damage and accidents compared with fast-acting roller doors.
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