The presentation from the FlexQube webinar about forkfree production from September 15, 2016. The presentation includes details about different types of tugger train system such as tongue and hitch or mother-daughter cart systems. What are the benefits by going forklift free in production areas and how to achieve it.

1. WEBINAR
FORKLIFT FREE 2016.09.15
© FlexQube AB 2011-2016. All rights reserved.

2. The following presentation is confidential and the recipient is obliged to not distribute the presentation or
the information contained herein to the people who do not have a direct need for it, or do not need to be
involved to evaluate the product and concept.
FlexQube owns all rights to the products, concepts and solutions in this presentation and the recipient, or the
persons the recipient of this presentation shows or distribute it to, do not have the right to use the
products, concepts or solutions in any way.

3. 85
FATAL ACCIDENTS ONLY
IN THE US
34.900
SERIOUS INJURIES
42%
FATALITIES RELATED TO
THE OPERATORS BEING
CRUSHED BY TIPPING
VEHICLE
$1,390,000 PER
COST OF DEATH
https://ohsonline.com/Articles/2013/09/01/Death-by-Forklift-is-Really-the-PITs.aspx
http://www.reliableplant.com/Read/10384/forklift-free-plants
http://www.seegrid.com/pdf/forklift_free_white_paper.pdf
There is no question human loss and liability cost relative to forklift injuries has been the No. 1
driver for forklift-free (also referred to as fork-free) plant floors.

4. 85
FATAL ACCIDENTS ONLY
IN THE US
34.900
SERIOUS INJURIES
42%
FATALITIES RELATED TO
THE OPERATORS BEING
CRUSHED BY TIPPING
VEHICLE
$1,390,000 PER
COST OF DEATH
https://ohsonline.com/Articles/2013/09/01/Death-by-Forklift-is-Really-the-PITs.aspx
http://www.reliableplant.com/Read/10384/forklift-free-plants
http://www.seegrid.com/pdf/forklift_free_white_paper.pdf
There is no question human loss and liability cost relative to forklift injuries has been the No. 1
driver for forklift-free (also referred to as fork-free) plant floors.

5. 4
5
3
22
1
3
5
4
38 m 110 m
1
REPLENISH
5X PALLETS
TUGGER TRAIN WITH 5 CARTS FORKLIFT

6. 20101960
LIFECYCLES
$ $ $ $

7. C
A
B
B
A
P O
N
M
L
K
H
G
F
ED
C
B
A
THE PAST FUTURE
PARTS ARE SUPPLIED MORE FREQUENT

8. A
B
A
B
RIGHTAMOUNT...
OFTHERIGHTMATERIAL...
INTHERIGHTCONDITION...
ATTHERIGHTPLACE...
INTHERIGHTSEQUENCE...
INTHERIGHTTIME!
3. PREPARATION 4. PRE ASSEMBLY
5. FINAL ASSEMBLY
2. WAREHOUSE
1. UNLOADING

9. THE PAST PRESENT FUTURE?
MATERIAL HANDLING AREA MANUFACTURING AREA
75% OFONITEMSPRODUCTIONCOSTISRELATEDTOMATERIALHANDLING
55% OFFACTORYSPACEISUSEDFORMATERIALHANDLING
http://clearpath.ottomotors.com/industry-4-0-ebook/
SELF-DRIVING VEHICLES FOR INDUSTRY
Innovation in an Interconnected World
Industry 4.0 and the power and potential of self-driving vehicles

10. LOAD CARTFORKLIFT FREE
= + +
MOVER
+
LAYOUT
FORKLIFT FREE PARAMETERS
PEOPLE
+ + +

11. MANNING AND TASKS? ERGONOMIC
REQUIREMENTS?
PUSH AND PULL FORCES? FREQUENCE AND
DISTANCE?
PEOPLE
UNION REGULATIONS UNDERSTAND WHY VEHICLE AND DRIVE
TRAINING
IT SYSTEMS?

12. HUMAN? PUSH UNIT? POWER CASTER? TOW TRACTOR
MOVER
AGV/AGC/SDV

13. PALLET?
TRANSPORT RACK?
PLASTIC CONTAINER?
BOXES?
MESH CONTAINER?
KITS? .
TOTES?
LOAD
• WHAT TYPES OF LOADS DO WE HAVE?
• WHAT IS THE CONSUMPTION RATES?
• HOW MANY PARTS ARE STORED IN EACH LOAD?
• HOW OFTEN WILL WE NEED TO SUPPLY?
• IS REPACKING NEEDED?

14. DROP OF ZONES?
SUPPLY ROUTES?
FLOOR QUALITY?
AISLE WIDTH?
RECEIVING AREA?
DRIVER VISIBILITY?
PICKING AREAS?
OUTSIDE ROUTES? PEDESTRIAN AREAS? FORKLIFT AREAS?
TRAVEL DIRECTIONS?
HILL DRIVING?
LAYOUT

15. PLATFORM TOW
BARS
HANDLE
BARS
TOP
STRUCTURES
CASTERSFLEXQUBE
BLOCKS
MOVER LOAD
LAYOUT
CARTS

16. FLEXTUBE
FLEXPLATE
FLEXQUBE
FLEXBEAM
The core in the
FLEXQUBE® concept
includes four different
building blocks. All
equipped with the
famous pattern that
ensures that all building
blocks can be combined
with each other into
endless number of
solutions.

17. DIRECT
MOTHER/DAUGHTER
LOWER INITIAL INVESTMENT
SCALABLE IN SMALL STEPS
ANY SIZE OF CART IN SAME TRAIN SET
NUMBER OF CARTS IN TRAIN SET IS FLEXIBLE
CART UPGRADES INDEPENDENT OF MOTHER CART
CAPACITY INCREASED BY ADDING MORE CARTS
QUICK TO CONNECT AND RELEASE CARTS
CARTS CAN BE RELASED INDEPENDENT
ENABLES SIMLPER DESIGN OF CART
HIGHER START INVESTMENT
WEIGHT OF MOTHER CART STEALS TOW CAPACITY
NUMBER OF MOTHER FRAMES DECIDES CAPACITY
DAUGTHER CART MUST BE ADAPTED TO MOTHER CART
MORE ADVANCED MAINTENANCE ON MOTHER CART
MORE MAINTENANCE ON CASTERS
CARTS MORE EXPENSIVE THAN DAUGHTER CARTS
CARTS NOT INDEPENDENT OF EACH OTHER
+
-
+
-
TOWTRACTOR

18. DIRECT
CONNECT
DIRECT
CONNECT

19. DIRECT
CONNECT
DIRECT
CONNECT

20. ONE SIDE FLOW
TWO SIDE FLOW
DAUGHTER CART ON GROUND DAUGHTER CART OFF GROUND
SIMPLE FRAME DESIGN
+
-
NO NOISE FROM CART CASTERS
FLEXIBLE CASTER POSITION ON CART+
CART RELEASE ONLY FROM ONE
SIDE
REQUIRES PLANNING OF ROUTE
ERGONOMIC ISSUES
GOOD ERGONOMICS
CART CAN BE PUSHED OUT FROM
FRAME
LESS RESTRICTIONS ON LAYOUT AND
PLANNING
+
-
- FORCE REQUIRED TO PUSH CART ONBOARD
THE MOTHER FRAME
NO NOISE FROM CART CASTERS
FLEXIBLE CASTER POSITION ON CART+
-
FORCE REQUIRED TO PUSH CART ONBOARD
THE MOTHER FRAME
MORE COMPLEX MOTHER FRAMESOUNDS AND VIBRATIONS FROM
DAUGTHER CART

21. 1 SIDE OFF
GROUND

22. 2 SIDE OFF
GROUND
2 SIDE OFF
GROUND

23. 2 SIDE OFF
GROUND

24. LIFT MOUNT TOW
NO NOISE FROM CART
CART CASTERS NOT IN GROUND
FLEXIBLE CASTER CONFIGURATION
FLEXIBLE AGV INTERFACE
+ +
LESS COMPLEX ROBOT DESIGN
ALL ENERGY USED FOR TRANSPORT
+
CAN PULL SEVERAL CARTS IN TRAIN
HEAVY WEIGHTS
-
CUSTOM MOUNTING INTERFACE
CASTER SET UP MUST ALIGN WITH
ROBOT
-
LIFT LIMITS CAPACITY
MORE WEIGHT ON ROBOT
DURING TRANSPORT
-
LARGE EQUIPMENT
CUSTOM MOUNTING INTERFACE
CASTER SET UP MUST ALIGN WITH
ROBOT
AGV
Automated Guided Vehicle
AGC
Automated Guided Cart
SDV
Self Driving Vehicle

25. LIFT MOUNT

26. BENDING?
STRETCHING?
FINDING?
UNPACKAGING?
REARRANGING?
BLIND PICKING?
A B DC
B A
B
HEAVY PICKING?
WALKING?
LOAD ERGONOMICS

27. THEYAREALLDESIGNED WITH FLEXQUBE BUILDING BLOCKS!
ROTATING CARTS PALLET CARTSMOTHER/DAUGTHER CARTS SHELF CARTS
TILT CARTS FLOW RACKS KIT CARTS TRANSPORT RACKS

28. 1 SIDE OFF
GROUND

29. MOUNT

30. DIRECT
CONNECT

31. DESIGN4ALLTM
DESIGNONDEMANDTM
DESIGN THE CART ON YOUR OWN FLEXQUBE DESIGN THE CART FOR YOU
THERE ARE TWO WAYS TO DESIGN YOUR FORKLIFT FREE APPLICATION

32. 2. MEETING 3. DESIGN 4. OFFER 5. DELIVERY
DESIGNONDEMANDTM We do the design for you.
1. PREPARATION 5. PURCHASE
Book your free DesignOnDemand session already today: design@flexqube.com

33. FUTURE
LOGISTICS
17 NOVEMBER
HANDLE
CHANGE
15 DECEMBER
DESIGN FOR
ERGONOMICS
01 DECEMBER
LEAN
PRODUCTION
22 DECEMBER
GO FORK
LIFT FREE
15 SEPTEMBER
MANAGE
PROJECTS
27 OCTOBER
INTEGRATE
WITH AGV´S
10 NOVEMBER
DESIGN IN
ONSHAPE
06 OCTOBER
FLEXQUBE WEBINAR CALENDAR 2016
10:00 EST 16:00 CET 10:00 EST 16:00 CET 10:00 EST 16:00 CET 10:00 EST 16:00 CET
10:00 EST 16:00 CET 10:00 EST 16:00 CET 10:00 EST 16:00 CET 10:00 EST 16:00 CET

34. • www.onshape.com
• Anyone can design
• No installations or license needed
• Design directly in your web browser
• FlexQube building blocks available in the cloud
• Fun and easy to learn
• Easy to share designs
• Get started! Contact design@flexqube.com for
online training
DESIGN4ALLTM Create on your own with

35. CONTACT US TODAY TO LEARN MORE ABOUT THE FLEXQUBE CONCEPT!
STANDARD BUILDING BLOCKS
Simple, fast and robust
DESIGN4ALL™
Do designs on your own
DESIGNONDEMAND™
Live design for your team
STANDARD LENGTHS
No cutting needed – just assemble
SOLUTIONS LIBRARY™
Get inspired and see other creations
VERSATILE
Solutions for all parts of the plant
http://sl.flexqube.com/
CONTACT
FORK LIFT FREE SOLUTIONS
All types of Tugger carts
www.flexqube.com
design@flexqube.com
sales@flexqube.com