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Lodge Manufacturing – Integration of application-specific forklift trucks and smart warehouse design helps boost productivity

Application

Lodge Manufacturing is an internationally-known manufacturer of cast iron cookware, founded more than 120 years ago in South Pittsburg, TN. It is recognised not only as one of America’s oldest, continuously operating cookware companies but also as an industry innovator, being the first to introduce pre-seasoned cookware to the market. Today, the company’s products are shipped worldwide and sold through big box stores, hardware stores, specialty retail outlets and through online e-commerce.

Challenge

For many years, the original Lodge foundry and a 3,700 m2 warehouse and distribution centre kept pace with demand, but in the mid-1990’s business began to increase dramatically. A foundry expansion was closely followed by construction of a new second foundry and 20,000 m2 distribution centre designed to handle the larger orders associated with the company’s traditional channels as well as smaller individual orders generated via e-commerce. Now, with capacity available to support the significant increase in demand, Lodge needed to select the right tools and processes that would enable them to effectively handle incoming inventory from two foundries while efficiently processing orders both large and small.

order picker with mast MPC Series from Crown


Solution

With the help of local Crown dealer, The Bailey Company, and warehouse design expertise from Crown, Lodge Manufacturing selected an entirely new fleet of forklift trucks designed to perform specific tasks associated with the new warehouse design. The company selected Crown’s TSP Series VNA trucks to replenish and retrieve the heavy cast iron cookware in its narrow aisle, high-bay facility. The RC Series stand-up forklift trucks were chosen for use on the docks for loading and unloading as well as in the racks for replenishment. Crown’s MPC Series multi-purpose forklift provided an ergonomically friendly order-picking solution that enables operators to adjust the pallet lifting height to avoid back and shoulder strain. While Lodge managers were familiar with the durability of Crown forklifts, they also solicited input from operators who praised the manoeuvrability, visibility and comfort afforded by the new fleet. Productivity in the new distribution centre has increased dramatically, with the new warehouse design, application-specific lift trucks, warehouse management system, new processes and a talented and dedicated staff all working together to more than double picking capacity.

stand-up forklift RC Series from Crown


Results
– The robust TSP Series’ MonoLift® mast and MoveControl® seat helps provide superior visibility and precision while operating in the narrow aisles, inspiring operator confidence

– The RC Series’ ergonomic and safety features enable operators to easily and safely manoeuvre the staging and dock areas while its FlexRide™ suspension provides all day comfort

The flexible and ergonomic MPC Series facilitates safe and efficient order picking with electronic steering, a low step height and lifting forks to minimise bending and stretching.

 

“I’ve been working with Crown for the past twenty years. Crown, in my experience, stands the test of time.”

Teresa Baugh
Distribution Center Manager
Lodge Manufacturing
South Pittsburgh, TN

 

About Crown Equipment Corporation – EMEA
Crown is one of the world’s largest material handling companies with a reputation for award-winning product design, advanced engineering and technology supported by superior after-sales service. Crown’s business philosophy utilises vertically integrated processes to design, manufacture and distribute forward-thinking innovative solutions that improve customers’ productivity and operating efficiency. Crown develops, produces and sells a broad range of forklifts, as well as automation and fleet management technologies.

The company’s global headquarters is located in New Bremen, Ohio, USA, with regional headquarters in Germany, Australia, China and Singapore. Its employees number more than 16,000 worldwide. Crown operates a service and distribution network that exceeds 500 retail locations in over 80 countries. To learn more about Crown’s ideas for helping customers advance the productivity of their operations, visit crown.com.

 

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Media Contacts

Jörn Erdmann
Crown Gabelstapler GmbH & Co. KG
Tel.: +49 (0)89-93002-313
E-Mail: joern.erdmann@crown.com
Website | LinkedIn

Duncan Tift
Adfield-Harvey PR
Tel.: +44 (0) 1952 752 500
E-Mail: duncan@adfield.co.uk
Website


Crown forklift trucks help boost productivity at Lodge Manufacturing - Crown Lift Trucks Newsroom

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