Full Case and Less Than Case Order Picking, Inspection & Packaging System

Full-case and less-than-case order picking, order inspection, and packaging systems. The system substantially reduces the associated walking and lifting requirements as well as increasing order throughput rates and picking accuracy. The system starts with an over/under high density pallet storage system with push-back staging of loads on the upper two rack levels and gravity flow lanes for full case picking to powered take-away conveyors on the lower level. The system then passes through a broken case picking area for small items to be picked from shelf levels in a rack-supported mezzanine configuration. Finally, all orders go to a sortation station where the system automatically segregates full-case orders and bypasses them around the manual inspection process. All other orders pass through a 100% inspection and packing process.

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 turnaround times, improved associate ergonomics, and direct and indirect cost reductions per finished part produced.

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 was critical to the operation due to the back pressure on the line when multiple containers were staged.

Work-in-Process KanBan Cell for Product Assembly Lines

A lean manufacturing product delivery system for handling work-in-process totes on powered conveyors and specialized carts between manufacturing processes. The picture shows four 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 four 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 (two upper left hand cells). Emptied totes are removed from the assembly processes by these conveyor cells as well. The conveyors interface with 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.

Pallet Jack Loaded & Unloaded Case Pick & Wrap System – Generation 1

The customer wanted to reduce the time allocated for stretch wrapping manually picked loads in a high-velocity distribution center. The solution allowed the pickers to deliver two picked pallets at a time to a low-elevation powered roller conveyor, push a start button, and go back to picking. Once the process starts the loads are singulated to a high speed wrapper that processes a load per minute and then the finished loads are released downstream for pick up by another pallet jack. Prior wait times per load wrapped were 150 seconds (2 minutes and 30 seconds). New wait times per load wrapped became 15 seconds, a 90% reduction in wait time that became immediately available for picking improvement.

Pallet Jack Loaded Case Pick & Wrap System – Generation 2

The customer wanted to reduce the time allocated for stretch wrapping manually picked loads in a high-velocity distribution center. The solution allowed the pickers to deliver two picked pallets at a time to a low-elevation powered roller conveyor, push a start button, and go back to picking. Once the process starts, the loads are singulated to a high speed wrapper that processes approximately one load per minute and then the finished loads are released downstream for pick up by a forklift truck at the shipping dock. Prior wait times per load wrapped were 150 seconds (2 minutes and 30 seconds). New wait times per load wrapped became 15 seconds, a 90% reduction in wait time that became immediately available for picking improvement.

Large Product Overhead and Conveyorized

Packaging System

The integrated crate assembly and crane-based lifting system is used to fabricate a variety of shipping crates plus load heavy, large, and bulky products into those crates as they flow down the floor-mounted gravity conveyor rails on a just-in-time basis for outbound shipment. Each station along the flow rails utilizes lift assist tools to ergonomically handle the progression of items needed to be loaded into each crate.

Small Parts Order Picking and Samples Packaging & Shipping Cell

The new powered conveyor system updated and centralized the picking and processing of orders within the existing less-than-case picking area. The system also provided a dedicated "Samples" picking operation along the same conveyor path. Implementing the new powered roller conveyor and control system provides a consistent stream of packages for the inspection and packing process. It also flows those ready-for-shipment packages through a sorting station to peel off the packages going to LTL trailers prior to delivering the balance of the packages to a dedicated outbound UPS trailer.

Finished Truck Shipment Accumulation Cell with Reverse Order Sorting and Dispensing Controls

Each pair of parallel-powered conveyors works as a pallet accumulation buffer and sortation carousel for outbound shipment. Shippable finished loads come from multiple upstream manufacturing lines. Each load is scanned into place as it is delivered to the selected buffer's infeed roller conveyor. A PC tracks each truckload's inventory against a master shipping list, and when the load is complete, the PC alerts the selected carrier to come pick up the load. When the delivery truck arrives at a dock the selected accumulation buffer conveyor circulates the loads past the discharge station and dispenses the accumulated loads to the forklift operator in the proper loading pattern.

Heavy Component Assembly and Packaging Cell

A flexible conveyor-based assembly system for heavy automotive drive line components with multiple work stations assembling the units in a single piece flow process. A secondary line, to the right of the assembly line, kits the custom units into retail packaging for shipment. The system provides better associate ergonomics with reduced lifting requirements, resulting in higher productivity per associate. Equipment designed, provided, and installed includes: zero-pressure accumulating conveyors, gravity conveyors, assembly work stations, Gorbel light bridge cranes and monorails, and purchased part shelving per assembly station.