Benefits to Using the Destuff-IT™

Productivity Gains

When your business banks on getting product both in and out the door, you need a reliable solution on the dock. The faster you are able to turn around product, the more efficient your DC becomes.

With proven productivity gains that not only reduce unload time, but also reduce or eliminate demurrage charges, standby charges and drop trailer charges, the Destuff-IT™ can also reduce the number of doors needed for the unload operation with more trailer turns per door.

Companies who start using a Destuff-IT™ machine over their usual step-stool method always see a reduction in the total number of man hours required to unload a trailer or container, many times by 50%. In addition, they may also see their unload times reduced by a similar number.

While the case rate will vary due to box size & weight, it is typically in excess of 800 units per hour. Also, the unit can be connected to an auto palletizer for even higher case rates and further labor reductions.

In addition, by increasing accessibility to the upper part of the trailer or container, supply chains using a Restuff-IT™ in their loading operation may also realize an increase in cube utilization.

The following chart identifies a serious contrast in efficiency realized when using a Destuff-IT™ vs the traditional method of unloading. These numbers were gathered at an actual customer location:

 Without
Destuff-IT™ Unit
Offloading with
Destuff-IT™ Unit
Destuff-IT™
Pilot Results
Average # of People2.73.71.139.40%
Average # of Man Hours11.14.8-6.3-57.00%
Average # of Cases/Man/Hour28340211942.10%
Average # of Cases/Hour6771540864127.60%
Destuff-IT™ Pilot Results Identified1.1 more people to offload container
57% reduction in manhours
42% improvement in cases/manhour
128% improvement in cases/hour

Ergonomic Gains

The Destuff-IT™ machine helps meet the needs of professionals in the supply chain such as health & safety representatives, operations personnel and general management. Many national companies with multi-shift operations and numerous distribution centres have realized the ergonomic benefits of this machine.

Operators can achieve greater throughput with less fatigue and muscle strain because of optimal positioning to the box wall. Workers stand on the operator platform and are able to access controls, drive and steer. With use of hydraulic power, an operator controls the vertical height of the platform in order to safely be positioned to the product being unloaded. While standing on the platform, a worker grasps the rotary handle which allows the pivoting conveyor to be easily guided left and right. This maneuverability allows the operator to position the conveyor near the product. This significantly reduces the risk of injury from repetitive lifting, twisting, carrying and overhead reaching.

CASE STUDY:

A North American uniform and work apparel company with a culture of embracing improved ergonomics throughout their manufacturing plants and distribution network, was looking for a better way to unload containers & trailers at their main distribution hub.

Their inbound docks received containers & trailers filled with floor-loaded boxed product. A team of 2 workers manually palletized the product inside the can. Once a pallet was complete, it was removed by forklift and transported to the warehouse. To assist workers, the company had purchased powered roller conveyor with an impact table and inclined conveyor to transfer product. This intervention did help, but workers still had to use step stools to reach ceiling height boxes or alternatively, climb on boxes to handle upper box wall cartons. Over the years, the conveyor impact section had taken abuse from boxes being dropped onto it and the section was becoming less reliable.

The company-wide focus on ergonomics was not a reaction to a number of recent incidents, but based on the corporate culture of preventing injuries. Their proactive approach identified the inbound dock area as having a high probability for injury. With this in mind, the company initiated a justification process to purchase equipment as an intervention strategy. The process assessed the number of motions saved over the course of one year, the number of potential injuries and established dollar value as a cost to the company.  The assessed cost was calculated to be $1.2 million, leading decision makers to search for an intervention device to reduce the risk of injury for their workers.

At a prominent industry trade show, the company discovered the Destuff-IT™ product line, manufactured by Engineered Lifting Systems & Equipment Inc. (ELS). After discussions with ELS, the company had a Destuff-IT™ product demonstration at their facility. One year later, they purchased a Destuff-IT™ with powered roller conveyor. The system integrated with their inclined conveyor.

While Health & Safety was the driving force behind the purchase of a Destuff-IT™, the company was pleased to realize productivity gains of 20% over their previous method of unloading. With an average of 900 case per truck, their inbound dock was capable of unloading 1.5 to 2 more trucks per day. Additionally, personnel who operated the Destuff-IT™ reported the machine improved their overall work experience. Also, after a full shift, they were not as fatigued or sore which allowed them to enjoy after work activities more.

Ergonomic Study

Engineered Lifting Systems & Equipment Inc. was approached by Dr. Steve Lavender at Ohio State University to conduct a study on the Destuff-IT™.  Dr. Steven Lavender, a professor of Integrated Systems Engineering at Ohio State University, endorses the advantages of using the Restuff-IT™ and often refers to this in courses he teaches. He is a member of the Human Factors and Ergonomics Society (HFES), American Industrial Hygiene Association, Orthopedic Research Society, the International Society for the Study of the Lumbar Spine, American Society of Biomechanics. He is also a Certified Professional Ergonomist (CPE) by the Board of Certification in Professional Ergonomics (BCPE). His expertise is often sought out by companies when they are investigating solutions and techniques to reduce worker injury and improve productivity.

The study’s primary goal was to objectively compare the biomechanical and kinematic impact between an extendable conveyor system and using an articulating belt conveyor when manually unloading and loading containers & trailers. Because of the scientific nature of this study, Dr. Lavender combined is findings from a controlled setting as well as “real life” practical application. He required that 2 two-week on-site demonstrations at distribution centers were necessary in order to train all workers involved and to gather a sufficient amount of data for both sections of his study. One focusing on the benefits of using the Destuff-IT™ machine (unloading), the other using the Restuff-IT™ machine (loading).

To receive a copy of Dr. Lavender’s published findings, please complete the CONTACT US form on our website or, contact your local Destuff-IT™ technical sales representative.

Dock Layout

Dock layout is key to achieving optimal results with the Destuff-IT™ machine. The unit is able to serve multiple docks and can be integrated with a variety of conveyor systems. Because the machine is self-propelled, it can easily move from dock to dock on its own power, as well as inside all types of standard-sized sea containers and trailers. The steering system is capable of negotiating dock leveler slopes and transition plates.

Portability & Versatility

The Destuff-IT™ machine is easily driven from dock to dock under its own independent power. These self-propelled machines have an integrated drive and steering system capable of negotiating dock leveler slopes and transition plates. Operators use easy to reach controls to travel forward, reverse, left, right and also zero radius turns.

In addition, the Restuff-IT™ bi-directional machine is the only solution that optimizes worker and conveyor positioning when loading and unloading.

All of the Destuff-IT™ product line can be integrated into power roller conveyor. Whether destuffing or restuffing, all machines connected to power roller conveyors are capable of pulling or pushing the conveyor sections inside the trailer or container. ELS engineers assess the product to be conveyed and recommend types suitable to the application or integrate units to existing conveyor.

FOR A BETTER WAY TO UNLOAD, CALL 1-800-263-9823