• Hardigg Industries: Double-Deep Storage Rack, Modular Office
• Bob's Discount Furniture: Double-Deep Storage Rack, Stockpickers
• OMG, Inc.: Adjustable Pallet Rack, Dock Equipment
• J. Polep Distribution Systems: Order Picking Systems
• Hasbro/Play-Doh: Mezzanines
• Lego Systems, Inc.: Loading Docks
• American Saw & Manufacturing Co. : Conveyor System, Order Fulfillment
• Foxwoods Casino: Warehouse Storage System
• Friendly Ice Cream Corporation: Conveyor System

Maybury created more than 1400 pallet positions within just 8500 square feet of space. (CLICK PHOTO TO ENLARGE)

Hardigg Industries
DOUBLE-DEEP STORAGE RACK
MODULAR OFFICE

For more than 20 years, Maybury account manager Bill Sieber has worked with Hardigg Industries, Inc. of South Deerfield, Massachusetts, providing material handling solutions that matched the company’s growth. As free floor space at Hardigg’s facility has become more and more sparse, they have relied on Maybury for solutions to maximize their storage and office space. Recently, when Hardigg’s rapid growth in injection-molded case business created a need to better optimize the floor space in their finished goods warehouse, they turned to Maybury. In addition to coming up with a plan to install a double-deep Interlake pallet rack system in this area, Maybury developed a plan for a Starrco Modular Office, which would allow Hardigg to make room for support staff for a new internal custom case assembly operation directly on-site in their receiving warehouse.

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36 Crown stockpickers and 1.2 million pounds of rack help keep Bob's warehouse running smoothly. (CLICK PHOTO TO ENLARGE)

Bob's Discount Furniture
DOUBLE-DEEP STORAGE RACK
STOCKPICKERS

In Norwich, Connecticut, Bob's Discount Furniture maintains a large storage and distribution center for furniture and bedding, from which approximately 1 million pieces were shipped in 2005. They receive solid containers filled with multiple units of the same product, then store the contents in this warehouse. To ensure the continued growth of the company and provide job security for their 1,500 employees, Bob's Discount Furniture had been wanting to expand their storage capacity and increase the volume of product handled. To that end, they have just completed a new 272,000-square-foot warehouse addition. One of the goals of the addition was to move all inventory under one roof. This would reduce furniture handling (reducing, in turn, damage to the furniture); decrease manpower required; and allow for higher profits. Additionally, Bob's Discount Furniture wanted to improve storage safety and provide a safer environment for their workers.

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Serco state-of-the-art dock equipment provides lift truck operators with a solid, secure platform for loading trailers with OMG product. (CLICK PHOTO TO ENLARGE)

OMG, Inc.
ADJUSTABLE PALLET RACK
DOCK EQUIPMENT

OMG, Inc. of Agawam, Massachusetts, is a manufacturer and supplier of fasteners and fastening systems for the construction industry. In order to double their storage capacity, they decided to build an entirely new distribution center. This would be accomplished with a 40-foot-high ceiling, rather than with a larger building footprint. Maybury Material Handling was selected early-on in the project to supply the pallet rack. Maybury's input included identifying floor loads and necessary reinforcements, based on rack weight, with consideration for the implications of rack and product placement on worker safety. Plans for OMG's state-of-the art distribution center included 12 docks with shelters, levelers and truck restraints. Keeping in mind OMG's focus on safety, Maybury was confident that Serco dock equipment would be an excellent choice for the new facility.

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State-of-the-art order picking is made possible by this new two-level pick module from Maybury. (CLICK PHOTO TO ENLARGE)

J. Polep Distribution Services
ORDER PICKING SYSTEMS

New products, more customers, and the need for faster movement had exceeded the capacity of J. Polep Distribution Services' existing order picking system. Maybury Material Handling was asked to look at the existing system and provide insight as to what could be done to structure a more efficient facility. Maybury designed a two-level pick module utilizing Interlake Material Handling's rack, conveyors, and carton and pallet flow units, integrated with a Maybury mezzanine, and Quantum Conveyor's automated induction and sortation systems. With its new Maybury-designed and -installed system, J. Polep Distribution Services has been able to increase the volume of product movement through the facility, in terms of both number of items and number of picks per item.

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A 50' x 100' mezzanine from Maybury helped Play-Doh increase productivity at their new facility. (CLICK PHOTO TO ENLARGE)

Hasbro/Play-Doh
MEZZANINES

When Hasbro decided to relocate their Play-Doh manufacturing facility, they chose Maybury to assist them with the restructuring of their Production Department. The relocation entailed moving all of the hardware for Play-Doh processing into a smaller area, so design efficiency was key. Maybury installed a 50' x 100' mezzanine with a 25' clear span between the columns. This 5100 sq. ft. mezzanine holds 36 bins of empty containers which are pulled on demand for filling. An auxiliary mezzanine measuring 2100 sq. ft. was installed for storage of mixing equipment. With this setup, Hasbro is able to fill 12,500 6 oz. cans per hour. Working two 12 hour shifts, they produce 300,000 6 oz. cans per day!

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Maybury installed 29 Serco Ultra Seals at Lego's loading area in Enfield, CT. (CLICK PHOTO TO ENLARGE)

Lego Systems, Inc.
LOADING DOCKS

When Lego decided to expand their loading docks, they came to Maybury for our expertise in material handling safety and productivity. To ensure the safety of Lego employees, we recommended the Dock Guard™ Barrier Lip option on Serco's HFC hydraulic levelers. In addition to installing twenty-seven hydraulic levelers with the barrier lip, Lego also had Maybury install twenty-nine of Serco's SL2060 Safety-Loc™ truck restraints. The Serco dock equipment installed by Maybury helped Lego to increase productivity and efficiency, while maintaining strict standards for employee safety.

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Maybury replaced American Saw's traditional incline/decline conveyor system with this vertical one. (CLICK PHOTO TO ENLARGE)

American Saw & Manufacturing Company
CONVEYOR SYSTEMS
ORDER FULFILLMENT

When American Saw & Manufacturing Company, a world-wide leader in the manufacture of saw blades, needed more floor space in two of their departments, they contacted Maybury. Maybury replaced a system of typical incline/decline conveyors with a vertical system that integrated directly with their main conveyor. The new system freed up floor space, cleared blocked aisles and speeded up product processing.

In addition to a lack of floor space in that department, American Saw's Literature Department was in need of more storage space. A newly installed integrated storage, conveyor and packing system has improved the workings of this department. Through the use of the proper shelving, conveyor, ergonomic lift load balancers and a walkie lift truck, Maybury, in conjunction with the staff of American Saw, was able to design a safer, more efficient literature order fulfillment system to meet customers' needs.

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This rack system is just one of a wide range of products used to put together the Mashantucket Pequots' massive warehouse storage system. (CLICK PHOTO TO ENLARGE)

Foxwoods Casino
WAREHOUSE STORAGE SYSTEMS

When the Mashantucket Pequot Tribal Nation needed a massive warehouse storage system for records, artifacts, supplies and retail goods related to Foxwoods Casino, Maybury's plan came out on top. Maybury utilized the products of many of its major vendors for this project. Interlake rack, Nelson steel decking, Maybury mezzanines, a Starrco modular office, Wirecrafters fencing, Crown lift trucks, Pflow Industries vertical reciprocating conveyors and a Railex garment handling system are all part of the new facility. The system now stores and supplies just about everything it takes to keep the world's largest casino running smoothly.

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Maybury designed a dual conveyor system for Friendly. (CLICK PHOTO TO ENLARGE)

Friendly Ice Cream Corporation
CONVEYOR SYSTEMS

Friendly Ice Cream Corporation of Wilbraham, MA, came to Maybury with the need for a system to convey and control several types of frozen products. The system would convey products from two separate production locations to one of two automated palletizers. The extremely limited space in which the system was installed, as well as the manufacturing process involved, dictated that Maybury design and fabricate several customized devices. The very cold environment of this installation also presented Maybury with special challenges. The system is now in full operation, providing highly efficient conveying of all types of frozen treats, from festive holiday rolls to cartons of "good old vanilla."

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