Assembly - February 2009 - (Page 65) Advertisement Advertisement CASE STUDY Stock Replenishment Reduced with Flow Cell Dynamic Storage Units tewart Industries, a full-service supplier to the automotive industry, set out to “reduce their 4x per shift stock replenishment down to 2”. Stewart’s management team emphasizes “efficiency in every aspect of its business, working to maximize synergy between cost and process control”. The installation of UNEX Flow Cells as dynamic storage units to feed their subassembly work tables met their criteria. Stewart Industries had redesigned the plant layout and knew the Flow Cell units were to be positioned between columns spaced 29’ apart, and the units had to store sub assembly parts for 3 family groups each in a designated area. UNEX worked closely with Stewart Industries and their distributor, Air Components, to define the min/max requirements of product throughput and the dimensions and number of units required. UNEX also realized that their SKUBE slotting analysis would assure an efficient and ergonomic placement of the inventory items. The results of the slotting analysis categorized several sku items that would be better placed alongside the Flow Cell units as pallets to reduce restock, maintain pick efficiency and still conform to floor space requirements. Stewart Industries agreed. A total of 24 Flow Cells measuring 78” wide x 168” deep with 3 picking levels were used. The units were designed with offset foot plates and casters to meet the customer’s request for “ease of movement and growth” as well as optimize floor space usage within the constraints of the columns. The storage and slotting of sub assembly components into UNEX Flow Cells met and exceeded their goal of reducing stock replenishment. Stewart’s VP of Operations was pleased saying “the project also eliminated a fork truck and material handlers when the new work process was implemented”. UNEX Manufacturing www.unex.com 50 Progress Place Jackson, NJ 08527 800-695-SPAN (7726) Conductix-Wampfler Assembly System S n Niepolomice, Poland, MAN Nutzfahrzeuge Group built the most modern truck plant in Europe, which, by 2010, will assemble 15,000 trucks annually in a continuous flow. A critical part of the assembly line is an integrated compressed air, electric power, and tool transport system designed by Conductix-Wampfler. “With MAN, we developed a complex roof structure to support and power all assembly tools along their respective line segments”, explains project manager Daniel Schlösser. The system gives the assembly operator great flexibility all along the line. A key component is the extruded aluminum W5-traxX “media rail.” This unique rail has a compressed air pipe formed within the extrusion. Compressed air, electric power, and data lines are carried from the rail to the assembler via an integrated cable chain system. The outside of the rail accommodates moving transports for assembly tools. The system can be expanded to include a contactless system to provide the exact position of the carts and automatic data collection. “The high load capacity, rigidity, and operational flexibility of the system allow us to use crane systems, handling technology, lighting, and compressed air supply systems wherever needed. The system can be adapted to changing requirements. Conductix-Wampfler planned and coordinated the whole project, assembled the steel framework, lamp controls, and stationary compressed air supply,” says MAN plant manager Marc Sielemann. Conductix-Wampfler Mike Bjornstad, Handling Products Market Manager 1-800-521-4888 (1-402-952-9327) mike.bjornstad@conductix.com I www.assemblymag.com February 2009 / ASSE M B LY 65 http://www.unex.com http://www.assemblymag.com
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