Features/Benefits Provided:   Boosts production 100% with no increase in manpower. Cuts order cycle time 40%. Reduces floor space requirements 80%. Smooth production flow with no downtime. Lowers Worker's Compensation claims.

To reduce production time, make more efficient use of available floor space and to reduce workers’ compensation claims, this manufacturer of gas cement logs for fireplace specialty dealers in the US and Canada decided to install an automated material handling system. Although the company was relatively small ($5 million in annual sales) a $350,000 capital expenditure for an automated storage and retrieval system (AS/RS) unit load was approved. The system was designed to function as a use-point management where the system consolidates the process of producing and curing 150 different styles of gas fireplace logs.

The use-point manager system installed at this facility is a one-aisle unit load that measurers 120’ long, 12’ wide and 19’ high with a capacity for up to 465 pallets. A loop conveyor transports the pallets in and out of the unit load. Latex rubber molds are prepared and fastened on the pallets. The pallets arrive at the pickup and delivery station at the far end of the AS/RS. The operator enters a confirmed store empty with the log product information. The storage and retrieval (S/R) machine picks up pallets of empty log molds and places each one in a designated storage location. Empty molds are sent via the S/R machine to be filled with log mixture.

A Real-Time System (RTS) directs the AS/RS to pull pallets of molds, which need to be filled and delivers it via a loop conveyor to prep, fill and send back to the AS/RS to cure. Once the RTS times the curing cycle it automatically directs the AS/RS to empty the finished pallets and send them to paint. The manufacturing process is then repeated.

The advantages of the system are numerous. The AS/RS frees up 80% of the floor space used in the company’s old process and keeps the production pipeline flowing smoothly with virtually no downtime. The system continually tracks storage locations for pallets of cured logs, and runs the daily operation from the orders stored in the computer, directing pallet retrieval, updating inventory counts in the system providing real time control of the entire manufacturing process. In addition, management is able to generate production control reports.

Since the install, this company has increased log production by 100% with no increase in manpower. Product quality has improved and the company has achieved a 40% reduction in order fill cycle time. Because of the reduction in lifting and manual handling, there has also been a dramatic decrease in workers’ compensation claims.

 

is a Proud Member of the AS/RS Product Section of Material Handling Industry of America

5202 Douglas Corrigan Way
Salt Lake City, UT 84116
Toll Free: 800-253-1003  |  Phone: 801-359-9900  |  Fax: 801-359-9911
info@DaifukuAmerica.com
www.DaifukuAmerica.com