Multi Level Work In Process KanBan Buffer for High Volume Production Process

The Manufacturing Cells (Not Shown) Adjacent To The Kanban Conveyors Produce The Components That Are Buffered In The Kanban Configuration. There Are Various Volume Levels Per Kanban Structure Based On The Work In Process Product Being Stored And Its Respective Container Types. Each Container Has A Substantial Gross Weight So The Heavier Loads Convey Directly To The Transportation Cart. Other Loads Transition to A Conveyorized Stacker Truck That Then Transfers To The Transportation Cart. Mechanical Singulation Of The Loads Onto The Transfer Cart Were Critical To The Operation Due To The Back Pressure On The Line When Multiple Containers Were Staged.

Flexible Product Assembly Cell With Common Base for Quick Cell Reconfiguration

One of Two Flexible Just In Time Lean Assembly Systems Consisting Of Multiple Lanes Of Stacked Raw Component Totes Ergonomically Presented To The Integral Assembly Line And Conveyorized Overhead Removal Of Empty Totes. The System Is Supported On A Common Transportable Frame That Supports Inbound Gravity Conveyors With Pneumatic Singulators, Customized Scissor Lifts For Multi Level Product Tray Presentation And Upper Level Empty Container Return Conveyors. The System Resulted In Reduced Finished Product Takt Times, Improved Associate Ergonomics And Direct and Indirect Cost Reductions Per Finished Part Produced.

Vertical Work In Process KanBan Cell for Product Assembly Process

An Integrated Vertical Carousel Storage and Horizontal Customized Cart Based Transportation System to Receive, Hold and Dispense 90 Pound Tote Containers Of Work In Process Components For A Flexible Manufacturing System.

Work In Process KanBan Cell for Product Assembly Lines

A Lean Manufacturing Product Delivery System For Handling Work In Process Totes On Powered Conveyors Between Manufacturing Processes. The Picture Shows Two Of The Eight Identical Conveyor Cells Within A Master Powered Roller Conveyor System. Each Shown Conveyor Configuration Was Designed To Stage 2-3 Hours Of Production So The Neighboring Processes Were Decoupled From Each Other. The Two Powered Conveyor Cells Shown Are Used To Accumulate And Deliver WIP Component Materials Into A Subassembly Process (Right Hand Cell) And Then To A Final Assembly Process (Left Hand Cell). Emptied Totes Are Removed From The Assembly Processes By These Conveyor Cells As Well. The Conveyors Interface To Custom Towed Transfer Carts Along A Common Aisle Between The Two Shown Cells. The Spatially Tight Environment Forced The Conveyor Flow Patterns To Fit Between And Around Other Manufacturing Processes And Minimize The Required Square Footage.

High Density High Velocity Deep Lane Frozen Unit Load Product Accumulation and Order Picking System w/ Evaporator Access Mezzanine

A Frozen Foods Manufacturer Needed To Increase Their Product Movement Velocity and Storage Density In A New Facility Under Consideration To Allow 24/7 Production Capability But Limit Shipping To M-F Operations. The Cart Based (High Density System) High Density Stoirage System Provides Substantial Cube Density In A Very Small Footprint While Also Providing Easy Maintenance Access To The Ceiling Supported Evaporators.

High Density High Velocity Deep Lane Frozen Unit Load Product Accumulation and Order Picking System

A Frozen Foods Manufacturer Needed To Increase Their Product Movement Velocity and Storage Density In A New Facility Under Consideration. The High Density Racking System Positions The Customer’s High Velocity Products Closest To The Shipping Docks Using A Cart Based Pallet Handling Method Capable Of Dispensing 30-40 Loads Per Hour To The Forklift Truck. Additionally, The Handling Method Limits The Forklift Truck Activity To Only The Front Or Rear Face of The Storage Structure. The System Also Positions The Balance Of The Customer’s Inventory Around The High Velocity Product In A Push Back Storage System Again To Provide Higher Storage Density With Good Product Velocity.

High Density High Velocity Deep Lane Frozen Unit Load Product Accumulation and Order Picking System

A High Volume Frozen Food Manufacturer Needed Substantial Cube Utilization Improvement Along With Improved Load Throughput. A Cart Based (High Density System) Storage System Was Designed And Installed That Provide Both Of These Requirements While At The Same Time Keeping The Distribution Operation’s Staffing Levels The Same. The New System Allowed The Customer To Retrieve All Their Inventory Managed By Third Party Logistics Companies Back To The Plant DC And Place It Fully Within Their Control. The New Freezer and Cart Based (High Density System) High Density Storage System Had A Short Payback Compared To The Customer’s Initial ROI Expectation.

Double Deep and Push Back Narrow Aisle Frozen Product Storage System

The Customer Needed To Maximize The Storage Capacity Of Finished Products In Their New Freezer Addition. The Provided System Utilized Single Deep, Double Deep And Push Back Racking Products To Get A Maximum Number Of Pallets Stored In The New Freezer.

Overhead Injection Molded Part Work In Process Accumulation Buffer

The Automotive Customer Needed To Accumulate Injection Molded Parts Across The Third Shift of Press Time To Support Two Shifts Of Downstream Production Time. The Free Standing Powered Dual Monorail System Segregated Right And Left Hand Work Into Two Independent Product Buffers. InJection Molded Parts Are Manufactured In A Just In Time Production Pattern On Third Shift, Accumulated In The Left And Right WIP Product Buffers And Held For The Next Two Shifts Of Final Assembly. The Parts Are Delivered To The Final Assembly Stations On Demand To Match Up To The Desired Discharge Pattern For The Manufacturer’s End Customer’s Requirement.

Wide Aisle Selective Rack and Order Picking System

100% Accessibility of Low Velocity Products Can Be Stored Using A Variety Of Selective Rack Designs With Conventional, Narrow Aisle or Very Narrow Aisle Forklift Equipment. Specifc Designs Are Developed Based On The Available Building Area, Building Height And Other Limitations Discovered During A Site Visit And System Design And Development.