An automatic answer

When automated storage and handling systems are first installed, it's likely that picking productivity rates will go through the roof. And it's not only picking rates that could receive a much-needed boost – if other forms of automated handling are used to move materials and products around the factory and warehouse, then consistency of delivery to the line or cell can be improved. "Production lines cannot be allowed to come to a halt because a part is not available lineside," says Phil Steeds. He is sales director for the UK arm of TGW, part of the Austrian TGW Group which designs and installs all manner of automated handling kit, ranging from small scale conveyors to high-end, high-bay fully automated storage and retrieval systems. He reckons the question for all manufacturers should be: what's the best solution to ensure that a part arrives just in time, in sequence and undamaged? "No matter over how many shifts, automated systems cannot be matched in terms of consistency of delivery and performance in delivering parts to a production line, which may look for many hundreds of orders per shift," he says. "These systems can allow manufacturers, particularly in discrete manufacturing, to find numerous cost savings that can lead to a quick payback." Personnel costs are undoubtedly the major saving, closely followed by floor space. Steed points out that by replacing conventional pallet racking served by forklift trucks, even narrow aisle lift trucks, with an automated storage and retrieval system, the same number of items can be housed within a much smaller footprint. "For a successful implementation, the priority is to provide the best possible fit to a customer's strategy and production facility. To achieve this, the systems integrator needs to consider factors such as volume, use, throughput, costs per storing position and pick." When it comes to delivering parts to the line, he says, a system comprising conveyors, elevators and shuttle cars can be designed for most production plants to ensure products reach the line in the correct sequence, at the right time and presented in the appropriate way – in pallets, totes, cartons or freestanding. "it's advantageous to minimise the movement of parts in a production facility. In many factories without mechanised materials handling, staff can walk great distances to transport goods, increasing risk of both delay and product damage. Placing a product on a conveyor, particularly with the proper load screening systems in place, not only saves time but adds to the productOs protection," he adds, "which is a particularly important factor when handling high value parts." An automated handling system can also be linked up to production management and ERP systems. Not only does this enable full control over picking and sorting of inventory but can also feed back important management data. It offers a greater element of control than can be provided through simply using barcode readers and the additional data is particularly important for those operations where strict asset tracking is important. Technical developments have also delivered more physical flexibility: an aisle within an automated storage and retrieval system, for example, can be lengthened easily to accommodate more stock with little impact on the performance of the machine. And the modular design of conveyor systems and accumulation units allow systems transporting goods around the factory or warehouse to be reconfigured when required. German industrial giant DaimlerChrysler turned to TGW when it required a materials flow system to support a new production line for the successor model to the Mercedes-Benz Sprinter, produced at the company's plant in Ludwigsfelde, Germany. A new small parts mini-load system has been set up at the centre of the plant to ensure the shortest possible routes to the assembly points. As soon as small parts are required by any of the assembly points, an automatic response prompts supplies to be sent from the small parts mini-load warehouse. The parts are stored in totes, delivered by the suppliers ready packed. Totes retrieved from the warehouse are placed on a loop conveyor by a stacker crane, also installed by TGW. The crane places the tote in the approach zone where the material loaded is distributed to three retrieval lines, depending on the assembly area. When they reach the assembly area, the totes are buffered, ready for pick up by lift truck for transport direct to the assembly location. The next part requirement is triggered here as soon as the existing stock of components is used up. Flexible offer Why are customers reluctant to use automated technology? Paul Fraser of Jungheinrich UK's systems and projects division says one reason crops up again and again. "The main reason tabled is flexibility," he says, making it crucial for suppliers to come up with an all-encompassing solution. "Today's forklift trucks can be bought for virtually the same price as 10 years ago, but they lift higher, move faster and last longer than before. The same can be said of automated systems – the technological advances in picking and conveyor systems, and crane systems, mean that goods can be moved around the facility at record speeds, stored at previously unimaginable heights, and the equipment has a life expectancy of 20 years or more." One manufacturer that knows the value of automation is Magna Automotive. The company's production site in Burton-on-Trent is part of its 'interiors division', which supplies injection-moulded internal door panels to a nearby OEM. It provides parts, on a just-in-time basis, for two vehicle models, with a four-hour notice period for incoming orders. Although Magna only makes door panels for two vehicle models, there are several variations. Early last year, due to a planned model change, Magna had to increase panel variations to meet the requirements for both the outgoing and new vehicle, which meant increasing variances by 17%. What's more, additional space was needed to accommodate the extra production equipment needed for this. The choice was simple: redevelop the existing facility or move into a larger, vacant building next door. To assess the most cost-effective solution, SDI Group UK was asked to design an automated system for the storage and retrieval of the panels at the existing site. A bespoke solution was required, which would free up space for new equipment while avoiding any disruption to operations. Magna also asked SDI to consider other requirements such as enhanced workforce productivity; maximising capacity for new business wins; and increasing operational visibility and control. In addition, any solution had to meet the needs of a JIT operation within the automotive sector – that meant high levels of accuracy, timeliness and product quality. Magna's facility had originally been built with a 10m internal height, yet the highest machinery stood at just 4m. This meant 60% of the cubic volume of the building was unused, so SDIOs solution entailed created a two-floor mezzanine structure measuring 18,000ft2. This has given Magna more than 10,000ft2 of additional production space to house new equipment. A powered, overhead conveyor system moves parts, placed on trolleys with load hooks, from the injection moulding machines into lanes on a platform above the production area. The parts are held here until needed, either by production areas or drop-off points for secondary manufacturing processes. Once parts are used, the empty trolleys are automatically transferred to the second mezzanine floor, above the platform storage area. Since the part weights vary, the system uses 250 customised brush breaks to control and slow trolley running speeds on the storage lanes and the unpowered parts of the system that rely on gravity. More than 3,500 sensor points provide critical stock data and enable Magna to monitor parts trolleys throughout the process – data is fed into a warehouse management system, also part of SDIOs solution. This capacity has enabled Magna Automotive to handle the increased product variations – it can make 1,330 door panels a day, from a total of 5,000-plus parts manufactured, stored and distributed within the facility. The dynamic storage area holds up to 1.5 daysO of parts and transports manufactured items from the injection moulding machines into a temporary storage area, before onward transfer to the production or process areas. As well as freeing up space, the system means workers no longer have to manually move parts between each stage of production. The installation was completed within the required timeframe, and Magna incurred no downtime.