Description

The solution is an impressive example of customer-focused development — and currently unique on the German counterbalance forklift market. Two years of development went into the vehicle, which was developed and manufactured by STILL in collaboration with Barrus Engineering for Voß Edelstahlhandel, with the aim of enabling sustainable and economical integration into everyday working life. The forklift truck has been in use since September 2024.

At the heart of the vehicle is the electrically adjustable floor plate. It can be adjusted vertically and horizontally with millimetre precision, enabling the driver’s seat to be tailored precisely to the body measurements of a short-statured employee. In addition, the fold-down backrest provides additional support for the driver’s back despite his shorter thighs. Combined with the individually adjustable entry step, additional handholds and hydraulic fork adjustment, this enables the driver to operate the vehicle independently and safely, with no limitations on loads of up to 5 tonnes. He has a clear view and direct access to all controls, giving him full control of the vehicle. Whereas he could previously only perform lighter tasks and was dependent on assistance, he can now significantly expand his field of activity, feeling safe and fully integrated.

At the touch of a button, the vehicle can be adjusted to standard size and thus used by all employees – an important criterion for sustainability and cost-effectiveness.

Innovations

There is currently no comparable solution for forklift trucks on the German market. Previous applications involving pedal extensions fail to offer a comparable level of accuracy, unrestricted visibility, safe vehicle control or occupational safety. Through this project, STILL, in collaboration with Barrus Engineering and Voß Edelstahlhandel, is offering a smart solution for sustainable and effective inclusion: designed around the needs of the customer and with a clear focus on intelligent, everyday-use solutions.

The employee concerned was closely involved in the development process from the outset, acting as a model for the dimensions and taking part in numerous tests. STILL enlisted the help of Barrus Engineering, a special design manufacturer, for the technical implementation. The limited space in the driver’s compartment, in addition to the high safety requirements, posed a particular challenge. Among other things, the chassis under the seat was modified, a linkage was created, the hydraulic block was moved under the floor panel, the pedals were decoupled from the floor panel, and the dashboard was modified. To ensure maximum safety and precise positioning, the base plate is fitted with intelligent sensors for position monitoring. Thanks to the reliable linear drive and the use of high-quality, lubrication-free brass guides, the complex construction requires no maintenance.

Market relevance

Inclusion in the workplace is a highly relevant issue. Smart solutions such as the custom-built STILL RX60-50/600 enable inclusion to be tailored to individual needs in a solution-oriented manner, break down barriers, promote tolerance and set examples. With comparatively little effort and a production time of just a few weeks, the concept can be adapted for other individuals and all STILL RX 60 models – under certain conditions, even existing RX 60 forklift trucks. Last but not least, the pilot project is a valuable reference for securing subsidies for inclusion solutions. After all, the Hamburg Integration Office covered all costs for inclusion-related modifications.

Against the backdrop of the ongoing labour shortage, concepts that provide motivated workers with attractive access to the labour market despite their disabilities are valuable and forward-looking. Specifically, in the case of the inclusion of people of short stature, the potential target group is large, so the project also has an economic dimension. After all, roughly one hundred thousand people of short stature live in Germany alone.

Last but not least, the project is highly relevant to the sustainability of intralogistics. It helps to retain employees and enables the flexible vehicle use. The adjustable floor plate and the possibility of retrofitting existing vehicles are particularly relevant aspects here.

Customer benefits

The customised design of the RX 60-50/600 enables the full inclusion of employees of short stature in the workplace. In addition to social responsibility, increased employee loyalty and satisfaction, and high occupational safety, this has a clear economic benefit for the customer: employees who were previously limited in their scope of work and dependent on assistance can now take on a wider range of tasks in the warehouse, move materials on various load carriers and up to a tonnage of 5 tonnes, and work completely independently – a valuable benefit given the labour shortage and high cost pressure in many companies.

In addition, the forklift truck’s flexible usability not only increases its cost-effectiveness but is also an important sustainability factor. There is no need to purchase and operate an ‘extra’ vehicle, as the inclusive solution is a fully-fledged part of the vehicle fleet.

Last but not least, the customer benefits financially from this solution: following an approval process, the costs of all custom-made inclusion-related products were covered by the Hamburg Integration Office.