A valued BSLBATT customer -A major U.S. auto parts manufacturer, faced material handling challenges when its 1.5 million-plus square foot auto parts plant decided to transform from a one-shift operation into a three-shift operation. The plant operates three shifts a day, 240 days a year, with 150 forklifts.
BSLBATT Battery works closely with fleet managers in the auto parts manufacturer’s logistics engineering group to recommend optimized power solutions for industrial equipment. The team’s responsibilities include assessing the plant’s material handling needs and optimizing the correct equipment selection and quantity.
CHALLENGE: 3-SHIFT OPERATION WITHOUT BATTERY REPLACEMENT
An American auto parts manufacturer approached BSLBATT Battery with a challenging and complex task. They were migrating to a 3-shift operation that didn’t lend itself to battery changes or extending charging periods.
In the past, the lead batteries used in the factory had been ideal for powering lifting equipment when a single shift is running. When the shift ends, there is enough time to recharge the lead batteries before the next shift. As new and emerging challenges such as time crunch, unpredictable order peaks, or increasing cost pressures emerge, however, they are changing priorities for facility operators. Power and charging efficiency have become important considerations.
Previously, forklifts would drive to a charging station a few hundred meters away to replace the battery. This creates serious problems and challenges for the day-to-day operations of intralogistics.
The issue would be resolved by the relocation of flexible, decentralized charging stations directly into the production area with small battery charging units close to the forklift working area.
Once lithium was identified as the preferred battery technology, the team conducted a risk analysis of lithium suppliers and their products. Forklift dealers serving the region recommend BSLBATT US Lithium Batteries as the preferred solution.
CLEAR SOLUTION: LITHIUM BATTERY FOR FORKLIFT TRUCKS
First, safety is paramount. The plant’s logistics engineering team determined that the lithium iron phosphate technology used by the BSLBATT Battery is significantly safer than other lithium battery technologies such as nickel manganese cobalt (“NMC”).
In response to these needs, BSLBATT Battery recommended its flexible fast charging system BSLBATT charger to the auto parts manufacturers, which can be precisely adapted to the needs of the operation process, thus making the work more flexible. BSLBATT fast chargers are distributed throughout the production area, so that the forklift can be used at any time, directly at the point of use.
Thanks to a special charging technology that ensures a continuous energy supply for 24 hours, it is possible to significantly increase productivity by saving time and costs. The smart Battery Cloud System can monitor battery voltage, temperature and battery state of charge while charging and control the charger accordingly. This makes it possible to charge the lithium battery to 95% of its capacity in just 1.5 hours.
THE RESULT: MORE SPACE, FEWER FORKLIFTS, HIGHER EFFICIENCY
The BSLBATT Lithium lift truck battery enables fast charging, provides longer runtime, higher/consistent strong voltage across each shift, and efficiently absorbs the regenerative energy of a Class II truck. As a result, the auto parts factory reduced its forklift fleet from 150 to 130. The excess equipment was moved to other facilities of the auto parts manufacturer, saving additional costs for the entire business.
Fleet managers see the deployment of BSLBATT Battery as a model for their other manufacturing and distribution facilities, and share many “learned lessons” with colleagues in the company’s sprawling materials handling department.