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JD GRAY ASSOCIATES CONTRACT INDUSTRIAL ENGINEERS MATERIALS HANDLING FOR ASSEMBLY, FABRICATION, W-I-P AND WAREHOUSE OPERATIONS Excerpts from our new book “CLASSIC PRODUCTIVITY SYSTEMS for the assembly manufacturer or distribution center” December 15, 2011 www.jdgray-associates.com

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JD GRAY ASSOCIATESCONTRACT INDUSTRIAL ENGINEERS

MATERIALS HANDLING

FOR

ASSEMBLY, FABRICATION, W-I-P AND WAREHOUSE OPERATIONS

Excerpts from our new book “CLASSIC PRODUCTIVITY SYSTEMS for the assembly manufacturer or distribution center”

December 15, 2011

www.jdgray-associates.com

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JD GRAY ASSOCIATESCONTRACT INDUSTRIAL ENGINEERS

ASSEMBLY, FABRICATION AND W-I-P OPERATIONS

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JD GRAY ASSOCIATESCONTRACT INDUSTRIAL ENGINEERS

PACED ASSEMBLY AND FABRICATION

The CLASSIC PRODUCTIVITY SYSTEM example of a Six Operator, Expandable Standard Rotary Assembly Conveyor with eighteen 24 Square Inch Pallets is as follows: Supervisor plots setting on variable dwell timer as to length of time wanted for the pallet to remain in a stationary position before indexing to the next station...this is the station control time developed during the line balancing segment of a paced assembly project. The entire chain-driven string of 18 pallets will index automatically eliminating the manual movement of assembly from one station to another which is approximately 24 inches at the same time at a speed of one foot per minute...then remain stationary for the time set on the variable dwell timer; this will create a pace for the six operators to finish their respective work task before the dwell time has been depleted signaling the next automatic index. Electrical, mechanical, wood, plastic or electro-mechanical assemblies are good candidates for a paced conveyor system. If increasing the number of workstations at a future date is desired, this conveyor is expandable to whatever number of pallets you require. An 'upfront initial gain' of 25%-40% savings potential will be created versus a bench or progressive line.

An overhead rail with trolleys apparatus can be added as well as overhead lighting mounted to the conveyor system, a tool rail running the entire length of each side of the rotary conveyor and electrical/pneumatic outlets spaced at four feet intervals servicing each of the six operators. The variable speed-indexing feature adjusts traverse timing depending on pallet width.

In house industrial engineering services should include: staffing determination, work task line balance, final conveyor specifications, dwell and traverse time development, process documentation including work station instructions - visual aids - bills of materials – tooling, work station layout, assembly system training and implementation assistance. A Pace conveyor can be linear slider bed or pallet, overhead monorail, heavy duty, square or rectangular rotary pallet, progressive or work center system.

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PACED ASSEMBLY AND FABRICATION SAVINGS BY PHASE

The rule of thumb for manufacturers today is that annual sales volume must exceed 1 million before a given product can be cost justified for full automation. The initial investment and payback periods are high when total automation is the goal.

Semi-automation is a cost-effective alternative. The equipment ingredients of such a system are:

• Synchronous platform conveyor • Vibratory part feed system • Robotics

Semi-automation addresses a segment of a given product for automation and creates special work cells to accomplish it. It combines the disciplines of materials handling, product mechanization and direct labor control systems. Labor gains of 75% are possible using this method of assembly. The typical consulting activity sequence necessary to convert products from a bench method of assembly to a semi-automated system is:

Phase One - Indexing Paced Conveyor System Work measurement Line balance Final equipment specifications Workstation layout Training Paced system installation

Phase Two - Semi-Automated Work Cells Design and fabrication Programming Electrical and mechanical installation

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The time-balanced Phase One system prepares for Phase Two semi-automation by eliminating future time bottlenecks for operations not to be mechanized. Phase One gains include:

From Bench orProgressive Line To Paced Assembly Line Labor Gain

Handling: 5% - 10%Excessive moves/storages Assembly where transportedMinor operations separate Coordinated work flow

Work area scattered Space saving by consolidation

Methods: 5% - 10% Tooling inadequate Tooling specialized Balanced by sequence Balance controlled Long work span Short station times Inefficient work place Optimum work place Quality separated Quality integrated

Performance: 15% -20% High responsibility Lower responsibility Output pegged to slowest Efficiency level created

Measurement late Measurement immediate Long training period Reduced learning curve Poor work habits Controlled work atmosphere

Total Average Improvement 25% -40%

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Phase Two gains in product mechanization leads to additional savings. They include:

From Bench orProgressive Line To Semi-Automated Cells Labor

Gains

Work Cell Sub AssemblyMechanization: 25-30%

Manual part placementinto container Bulk hopper part feed

Manual removal of part from container and alignment into fixture

Precision vibratory bowlpart positioning into fixture

Manual pneumatic/electricpart fastening Robotic part fastening

Work Cell S/A toPaced Assembly F/ALine Handling:

5%

No precision platformPrecision in-line pacedconveyor platform positioning

Manual placement of subassembly to final assembly

Robotic pick from S/A work cell and place on fixturized paced conveyor F/A platform

Total Average Improvement 30-35%

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Precision indexing pallet of the semi-automatic conveyor allows for use of robotic assembly of items such as axial lead printed circuit board components on reels, which can be setup without disturbing other on-line manual operations, as well as grouping existing 'islands of automation' into an on-line work flow and thereby eliminating the work-in-process materials handling between cells. Should the customer want to automate one (1st of the six) station by replacing an operator with robotic assembly, a standard rotary precision pallet locating system for one work cell is required for one shot pin locating device and eighteen pallet shot pin blocks. This will precisionly locate one pallet in front of the station to be automated - customer supplies the actual robot.

DELUXE ASSEMBLY CONVEYOR WITH ALL STANDARD OPTIONS

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STOCKROOM AND FINISHED GOODS

The CLASSIC PRODUCTIVITY SYSTEM example for a stockroom sequence of events originates when component parts are received, inspected and placed in tote trays that are identified by bar code then located into an inventory Live Storage and Retrieval System carousel. As stock orders are received and scheduled, component parts/totes are removed from the inventory carousels and placed in their respective manufacturing containers. The containers are then kitted into new totes… a routing bar code is then applied to the tote and automatically randomly staged in a work-in-process retrieval carousel by robot. Workstations are grouped by product on a transporter that services the paced assembly conveyors. The dispatch of a work-in-process tote to a workstation is initiated by the operator requiring a reserve tote when he/she moves the old reserve tote into its working tote position. The signal created by this action triggers movement of the proper work-in-process carousel (containing the next like-tote) to stop in front of the robot which then ascends to the proper shelf level of the bin, removes the tote from the shelf and then places the tote on the outbound dispatch conveyor. The tote bar code is read by a scanner that controls the deflector arms of the transporter. Operation sequence and location are determined, recorded and routed automatically.

The final operation of the work-in-process bar code routing will be ‘Send and store in a finished goods carousel’. The day’s picking for the finished goods carousel sequence begins the preceding night when customer orders are downloaded from the company’s mainframe to the PC at the operator workstation. The finished goods carousel software organizes the orders into batches of eight. It recognizes and organizes picks by the number of lines on the order which minimizes carousel rotation time to speed throughput. The insertion/extraction robot selects totes from the carousel as directed by a computer and routes them to picking workstations for selection and packaging. Partially filled totes are returned after picking to the finished goods carousel…empty totes are diverted to kitting stations for rerouting into work-in-process carousels.

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A work-in-process/inventory and finished goods Live Storage and Retrieval System (LSRS) Carousel will interface with a transporter conveyor system and deliver components to all workstations. The LSRS has the following advantages:

• Modular design permits easy installation, expansion or movement

• Unique bin design distributes shelf loads through two sides and back of bin, forming a rigid box structure

• Variable concepts to select from including pick and pass, remote picking, parallel picking and sort & consolidation

• Maximizes square & cubic foot utilization as well as storage density using double and triple deck carousel stacking

• Multiple orders picked sequentially

• Maximizes throughput – no walking, searching or lifting – up to 600% increase in picking rate

• ‘Hot Picks’ can be integrated into system without disturbing the flow of downloaded stock orders

• Insertion/extraction robot can pick from multiple carousels

• Exacting quality of the picked item that conforms fully and reliably to customer requirements

• Computer software that is upgradeable

• High security of items stored as carousels are easily enclosed

• High capacity loads up to 1,000 lbs per bin

• Centralized distribution of parts

• Eliminates need for material handling indirect labor operators

• Typical stockroom and finished goods inventory reduction is 10%

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WORK-IN-PROCESS

The CLASSIC PRODUCTIVITY SYSTEM example of an assembly w-i-p sequence of events originates when component parts are received, inspected and placed in tote trays that are identified by bar code then located into an inventory Live Storage and Retrieval System carousel. As stock orders are received and scheduled, component parts/totes are removed from the inventory carousels and placed in their respective manufacturing containers. The containers are then kitted into new totes… a routing bar code is then applied to the tote and automatically randomly staged in a work-in-process retrieval carousel by robot. Workstations are grouped by product on a transporter that services the paced assembly conveyors. Assembly operators are fed their respective components in tote trays, by the top conveyor on the dual level transporter conveyor system.

DUAL LEVEL TRANSPORTER

RESERVE TRAY

DEFLECTOR ARM

The transporter brings in totes of new work (top level) and takes away totes of completed work (bottom level). A TMC (transporter master control) panel is positioned in the centralized work-in-process area by the live storage and retrieval carousel used to stage the in-process tote trays. The dispatch of a work-in-process tote to a workstation is initiated by the operator requiring a reserve tote when he/she moves the old reserve tote into its working tote position. The signal created by this action triggers movement of the proper work-in-process carousel (containing the next like-tote) to stop in front of the robot which then ascends to the proper shelf level of the bin, removes the tote from the shelf and then places the tote on the outbound dispatch conveyor. The tote bar code is read by a scanner that controls the deflector arms of the transporter. Operation sequence and location are determined, recorded and routed automatically.

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Install a dual level transporter conveyor system to interface with a W-I-P stockroom and deliver components to all workstations. The dual level transporter conveyor system has the following advantages:

• Reduce thru put time

• Central control points for handling, storage control

• Report capability for part location and operation status

• Priorities can be expedited

• All W-I-P in either controlled transporter reserve stations or carousel storage bins for accountability

• Inventory turns quicker due to controls, recognition and report feedback time reduction

• Higher worker productivity

• Better interaction with other operations and departments

• Reduction of backlog

• Production control easier by better tracking

• Cycle time reduction

• Reorder points, stocking levels and purchasing requirements decreased

• Elimination of ‘wait for work’ intervals that cause hidden downtime

• Better inspection control

• Major changes in routing can be made without layout changes

• Expandability without layout change

• Layout not dictated by sequence of build or departmental groups

• Typical work-in-process inventory reduction is 20%

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3.3 SAMPLE LAYOUT

The sample layout depicts the interaction of three basic conveyor systems types customized for each application. The first type is a live storage and retrieval carousel used for the (3) staging area of incoming component parts and (3) staging of finished goods and (1) assembly work-in-process and (1) fabrication work-in-process. The second type is a single, dual level (80) station transporter used for part supply to and from kitting, w-i-p staging, assembly and fabrication. The third type is a semi-automatic, paced conveyor with work cell robotics for the assembly of (6) different products.

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FINISHED GOODS

LSRS

RAW MATERIALS

------- KITFABRICATION - WIP ASSEMBLY - WIP

R

------- KIT A

SSY- V

EY

OR

W

OO

FER

T

WEE

TER

TWEETER

WOOFER

WOOFER

WOOFER

P I C K

RECEIVING AND REC INSPECT

TRANSPORTER

LOCKERS

AND

RESTROOMS

CAFETERIA

PLANT MGR OFFICE

INV MGR

MFG SUPV (7)

MFGMGR

MFGMGR

MATMGR

FIN GDS

MATSUP

RACK

P

P

P

REPLEN P

P

REC TRUCK

REC TRUCK

SHIP TRUCK

SHIP TRUCK

OUTER WALL BEGINNING OF OFFICE AREA

BEGINNING OF OFFICE AREA

RESERVE STA

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PACED CONVEYOR LINEAR TYPES

LINEAR SLIDER BED

OFF LINE FIXTURES AND AUTO CELLS – 50 LB MAX. FOR LONGER (UP TO 120”L X 36”W X 24”H) PRODUCTS.

OPPOSITE LINE ACCESS.

LINEAR PALLET

IN-LINE FIXTURES AND AUTO CELLS - 150 LB MAX.

FOR SMALLER (UP TO 24”L X 24”W X 24”H) PRODUCTS.

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PACED MANUAL PACKAGING CONCEPTS USING A LINEAR SLIDER BED CONVEYOR – EXAMPLE

Manual Packaging Assumptions

• There is an existing continuous running slider bed belt conveyor or live roller conveyor or bench operation. This type conveyor will have to be modified (timer added, index and dwell versus continuously running, belt lined etc) or replaced to achieve a savings objective.

• No current time study exists to optimize output by synchronizing the container machine cycle with a packaging operation division of work.

Manual Packaging Recommendations

• The lower responsibility and immediate performance and quality measurement features of the indexing paced conveyor system will optimize output.

• Proper line (time) balancing at a normal work effort will lower labor requirements.

• Direct labor savings or output increase between 25% - 30%

MODIFY EXISTING (OR NEW) TO INDEXING LINEAR SLIDER BED CONVEYOR

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INDEX AND DWELL VS CONTINOUS RUNNINGLINED BELT

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LINEAR SLIDER BED - MANUAL PACKAGING CONVEYOR –

ALTERNATING PALLET CONCEPT

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TOPS 1

TOPS 2

TOPS 3

TOPS 4

1

2

3

4

1

2

4

- FORM MACHINE-

TOPS

- TRIM MACHINE–

TOPS

CARTONS and

POLYBAGS

BOTTOMS

CARTONS and

POLYBAGS

BOTTOMS

PALLET

PALLET

PICK AND PACK CELLS

CARTONS and

POLYBAGS

BOTTOMS

PALLET

CARTONS and

POLYBAGS BOTTOMS

PALLET

MODIFY EXISTING (OR NEW) TO INDEXING

SLIDER BEDCONVEYOR

3

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LINEAR SLIDER BED - MANUAL PACKAGING CONVEYOR –DIVISION OF WORK CONCEPT A

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TOPS

- FORM MACHINE-

TOPS

- TRIM MACHINE–

TOPS

- PICK –

BOTTOMS

- FORM -

CARTONS

EMPTYPALLETS

PALLET

PALLET

PACK BOTTOMS

andPOLYBAGS

PACK TOPSand

POLYBAGS

MODIFY EXISTING (OR

NEW) TO INDEXING

SLIDER BEDCONVEYOR

BOTTOMS

FORMED CARTONS ON SIDE

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LINEAR SLIDER BED - MANUAL PACKAGING CONVEYOR – DIVISION OF WORK CONCEPT B

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TOPS

- FORM MACHINE-

TOPS

- TRIM MACHINE–

TOPS

- PICK –

BOTTOMS

- FORM -

CARTONS

EMPTYPALLETS

PALLET

PALLET

PACK TOP & BOTTOM

and POLYBAGS

PACK TOP & BOTTOM

and POLYBAGS

MODIFY EXISTING (OR

NEW) TO INDEXING

SLIDER BEDCONVEYOR

BOTTOMS

FORMED CARTONS ON SIDE

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OVERHEAD MONORAIL

FEEDS HEAVY OR PAINTED COMPONENTS TO PACED ASSEMBLY LINE. SPEED OF MONORAIL IS DETERMINED BY HANGING PATTERN FOOTAGE AND OUTPUT REQUIREMENT OF

ASSEMBLY LINE. 350 LB MAXIMUM – FOR THE LARGER (UP TO 30”L X 30”W X 72”H) PRODUCT FAMILIES.

HEAVY DUTY ROTARY

IN-LINE FIXTURES AND AUTOMATION CELLS - 350 LB MAXIMUM. ROBOTIC EQUIPMENT WITHIN CONVEYOR FOOTPRINT.

FOR THE LARGER (UP TO 30”L X 30”W X 72”H) APPLIANCE TYPE PRODUCT FAMILIES.

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SQUARE RECTANGULAR ROTARY PALLET ROTARY PALLET IN-LINE FIXTURES AND AUTOMATION CELLS IN-LINE FIXTURES AND AUTOMATION CELLS 150 LB MAX. 150 LB MAX ROBOTIC EQUIPMENT WITHIN CONVEYOR FOOTPRINT ROBOTIC EQUIPMENT WITHIN CONVEYOR FOOTPRINT FOR SMALLER (UP TO 24”L X 24”W X 24”H) PRODUCTS. FOR SMALLER (UP TO 24”L X 24”W X 24”H) PRODUCTS OPPOSITE LINE ACCESS.

PROGRESSIVEOFF LINE FIXTURES AND AUTOMATION CELLS – 50 LB MAXIMUM. DIVISION-OF-WORK BY SHELF LEVEL.

RANDOM SEATING. . FOR THE SMALLER (UP TO 24”L X 24”W X 24”H) PRODUCT FAMILIES

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WORK CENTER SYSTEM

OFF LINE FIXTURES AND AUTOMATION CELLS – 25 LB MAXIMUM. DIRECT FEED BY DUAL LEVEL TRANSPORTER.

FOR THE SMALLER (UP TO 24”L X 9”W X 24”H) PRODUCT FAMILIES.

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MODEL - HOSE THRU TEST

DUAL LEVEL TRANSPORTER

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TABLE

TOTE AREA

TABLE A

TABLE BTOTE AREA

(MOTOR WITH HOSE & NOZZLE)

C R I M P

CRIMP

C R I M P

TEST

TEST

FULLTOTE

WIPTOTE

EMPTYTOTE

OUTBOUNDGRAVITYROLLER

CONVEYOR

INBOUNDGRAVITY ROLLER

CONVEYOR

WORK CENTER SYSTEM

COLUMN

FULLTOTE

STA 2

STA 3

STA 4

STA 5

STA 1

CRIMP HOSE, PLASTIC NOZZLE & END PIECE. TUBING TO GAUGE. ASSEMBLE (1) CLAMP.

ASSY (1) CLAMP. CRIMP PRESS

GAGE TO MOTOR

STATIONS FIVECONVEYOR DWELL .236 OR 14.2 SECMOTORS PER INDEX 1OUPUT PER SHIFT 1900

ASSEMBLE/CRIMP HOSE & END PIECE TO MOTOR.

ASSEMBLE HOSE, PLASTIC NOZZLE & END PIECE.

ASIDE TO TABLE (B). PLACE TOTE TRAY ON TABLE (A)

TEST OPERATORS

PROCESS EVERY OTHER

MOTOR. MOUNT PAD

TO PRESSURE

GAGE. TEST

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OVERHEAD MONORAIL AND TOWLINE SYSTEM

PLANT-WIDE GROUP PIECE WORK INCENTIVE PLAN

The incentive plan involves the development of an industrial engineered group standard. There would be a bonus pay based on group shift output. Footage required for parts hanging pattern matched with monorail speed to determine performance standard in feet per minute.

In the case illustrated, the towline system would pull buses with tires and move at the same speed as an overhead monorail. There would be seventy-two workers participating in this industrial engineered plant-wide group piecework incentive plan. Both systems would be in the shape of a closed loop rectangle. The overhead monorail would have the same hanging pattern every 60 feet, which approximates the length of one bus. Within the overhead monorail-hanging pattern, hooks would be spaced every 4 feet for different painted parts that would weigh 100 pounds maximum. There should also be 20 emergency stops located throughout the system. The speed of the overhead monorail would be variable from 0 feet per minute to 2 ft per min with a speed of 1 foot per minute representing a normal work effort. The group incentive would be based on this speed and as the feet per minute increases so would the group incentive pay.

FEET PER MIN

SHIFT CALCULATION

PIECES PER SHIFT PERFORMANCE HOURLY

PAY1.000 480 FT / 60 FT PER

BUS 8 100% $10.00

1.125 540 FT / 60 FT PER BUS 9 105% $10.50

1.250 600 FT / 60 FT PER BUS 10 110% $11.00

1.375 660 FT / 60 FT PER BUS 11 115% $11.50

1.500 720 FT / 60 FT PER BUS 12 120% $12.00

1.625 780 FT / 60 FT PER BUS 13 125% $12.50

1.750 840 FT / 60 FT PER BUS 14 130% $13.00

1.875 900 FT / 60 FT PER BUS 15 135% $13.50

2.000 960 FT / 60 FT PER BUS 16 140% $14.00

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OVERHEAD MONORAIL TOW LINE

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BUS

BUS

BUS

BUS

BUS

BUS

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WAREHOUSE OPERATIONS

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PACED ASSEMBLY WITH LIVE STORAGE AND RETRIEVAL CAROUSELS

SCENARIO: PACKAGING OPERATION SHOULD NOT BE DIRECTLY TIED TO A VARIABLE MACHINE CYCLE

OBSERVATIONS AND FINDINGS - EXAMPLE

A current method of tying the packaging function directly to a thermoforming machine cycle is inefficient. There is an average of 32.5 seconds average packing time per operator versus 52.5 seconds average machine cycle time or a 38% loss to balance which is over the normal 5% expectancy. Operator packing time can also double or 65 seconds, when there are quality issues such as recounting stacks, replacing missing containers to even out a stack count of 25, removal of defective containers and replacing defective containers. In this situation the packaging operator becomes overwhelmed with stacks of containers being fed at a much higher rate than it is possible to package. The permanent assignment of packaging operators to a thermoforming machine cell each day is inefficient as each operator absorbs 5 hours of downtime per week during machine mold changeovers when not performing housekeeping and scrap cleanup.

The packaging operator loading full bulk cartons of tops or bottoms on combo orders to save warehouse space is risky business. When it is time to bring the full W-I-P cartons from the warehouse and the time for a machine operator to unload half the carton contents (i.e. tops) to make room for containers being packaged directly from machines (i.e. bottoms), the chances of a full bulk carton slipping thru both packaging operators is enhanced with all the other responsibilities of a machine operator and the overburdened packer right after a machine mold changeover.

RECOMMENDATIONS

The packaging function should not be performed at the thermoforming machine but in a remote area. Since machine cells are assigned both bulk and combo orders, all products from all machines should be affected by the recommended system. Stacks of formed and trimmed containers coming directly from a thermoforming machine cell should be inspected, sorted and placed in a tote tray with lids then moved to a remote area to be temporarily staged in a storage device that will directly feed a paced packaging system using a work-in-process buffer with robotics. By doing this there will be no time imbalance between the packer and the machine cycle causing lost hours and incomplete/damaged stacks, no operator downtime waiting for a new mold changeover to take place, and no loading of full cartons for combo orders to reduce warehouse space causing customers to occasionally receive bulk cartons instead of combo cartons as all in-process half containers will be in tote trays.

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TOTE FLOW RACK – Three sections. Two tote tray section comprising of four tiers of ten 50’L X 24” W gravity roller containing 1000 totes or a two-hour WIP supply. Total of 40 lanes each equipped with a lightree visual and scheduling programming devices as well as a braking system in each lane – Installed $125,000. One pallet section comprising of two tiers of one 50’L X 48”W breaking gravity roller – Installed $25,000.

SYNCHRONOUS PRECISION INDEXING CONVEYOR – Fixtures mounted to hold formed carton in an upright position. Standard Linear or Rotary Assembly Conveyor Model 2424, 12' 6" OL, 18 pallets, three operator with four supports. Standard options include variable speed indexing, fluorescent lighting fixtures, and electrical outlets beneath pallet, upper supports to support lighting fixtures, pneumatic quick disconnect with air piping, tool tray railing, and overhead rail with trolleys. Standard Precision Pallet Locating System. One shot pin locating device and 18 pallet shot pin blocks - Installed $55,000

AUTO BOX – Fully automatic case former with hot melt glue bottom case sealer. Hot melt glue top case sealer. Top and bottom pressure sensitive case taper. Intermediate case-transport powered conveyors. Carton feed magazine. PLC controlled – Installed $150,000

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PICK AND PLACE ROBOT – Multi-axis-servo, multi-end-effector, conveyor synchronous unloader – Installed - $150,000

LIVE STORAGE AND RETRIEVAL CAROUSEL – Top drive carousel for standard and light duty applications controls using a footswitch. Fifty-six-bin unit, 20-inch bin depth, 85-inch bin height and 24.5-inch bin width, with adjustable dust free wire shelves on varying spacing, overall bin height including single yoke is 104.15 inches, shelf rating of 75 lbs, shelf spacing six inch standard. Each bin includes lightree visual and scheduling programming devices. – Two Installed Units - $170,000

INSERT AND EXTRACT ROBOT - Parallel jaw gripper, variable servo-controlled gripper clamping pressure, precision linear bearings on gripper clamp and reach axis, all electric operation, spring-set platform holding brake, chain break sensors and catch brakes on masts, over-speed sensor, path-clear sensors, automatic chain take-up, powder coat finish, stainless steel bed and software controls – Two Installed Units - $220,000

TOTE TRAYS – Used in both LSRS and robotic phases. Insert and extract robots require rigid and identical dimensional boxes for high thru put removal – two thousand totes - $50,000

TRAY INSERTS – Used only during the fully automation phase. Partitions to keep counted and stacked containers upright for pick and place robot removal – two thousand inserts - $10,000

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JD GRAY ASSOCIATESCONTRACT INDUSTRIAL ENGINEERS

PACED ASSEMBLY WITH LIVE STORAGE AND RETRIEVAL CAROUSELS

ROI AND SKETCH OF PROPOSAL

SAVINGS POTENTIAL

PACING PACKAGING CONCEPT USING FLOW RACK FOR TWO-HOUR WORK IN

PROCESS

Pacing concept using four operators operating a synchronous precision indexing conveyor and flow rack for a work-in-process buffer on each of the four shifts. Typical savings: Forty-eight packaging operator savings = 96,000 hours @ $12 per hour = A total of $1,152,000 in direct labor savings.

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JD GRAY ASSOCIATESCONTRACT INDUSTRIAL ENGINEERS

PACING PACKAGING CONCEPT USING FLOW RACK FOR 2-HOUR W-I-P

-

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FORM GLUE/TAPE

CARTONBOTTOM

PICK & PACK TOP,

BOTTOMand

POLYBAGS

FIXTURIZED UPRIGHT CARTONS

(LINEAR)SYNCHRONOUS PRECISION INDEXING CONVEYOR

CARTONS

FLOWRACK

Load pre counted

container stacks into

FLOWRACK during breaks,

lunch and after shift

ends

RETURN-ON-INVESTMENT

TYPICAL SAVINGS - $1,152,000 -----------------------------------

EQUIPMENT BUDGET COST –FLOW RACKS 150K, SYNCH

CONVEYOR 55K, TOTE TRAYS $50k- $255,000

CONSULTING FEE/EXP - $51,000

TOTAL COST - $306,000

ROI – 3.2 MONTHS

SEAL GLUE/TAPE

CARTONTOP

TOPS

FLOW RACK

BOTTOMS

FLOWRACK

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JD GRAY ASSOCIATESCONTRACT INDUSTRIAL ENGINEERS

PACED ASSEMBLY WITH LIVE STORAGE AND RETRIEVAL CAROUSELS

ROI AND SKETCH OF PROPOSAL

SAVINGS POTENTIAL

SEMI-AUTOMATION CONCEPT USING LSRS FOR TWO-HOUR WORK IN PROCESS

Pacing concept using four operators operating a synchronous precision indexing conveyor and LSRS for a work-in-process buffer on each of the four shifts. Typical Savings: Forty-eight packaging operator savings = 96,000 hours @ $12 per hour = A total of $1,152,000 in direct labor savings. This alternative incorporates the exact LSRS and indexing conveyor required for the full automation concept.

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JD GRAY ASSOCIATESCONTRACT INDUSTRIAL ENGINEERS

SEMI AUTOMATION CONCEPT USING LSRS FOR TWO-HOUR W-I-P

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FORM GLUE/TAPE

CARTONBOTTOM

PICK & PACK TOP &

BOTTOM

BOTTOMS

LSRS

TOPS

LSRS

FIXTURIZED UPRIGHT CARTONS (LINEAR)SYNCHRONOUS PRECISION INDEXING CONVEYOR

CARTONS

FLOW RACK

Load pre counted

container stacks into

LSRS during breaks, lunch and after shift

ends

RETURN-ON-INVESTMENT

TYPICAL SAVINGS - $1,152,000 -----------------------------------

EQUIPMENT BUDGET COST –LSRS 170K, SYNCH CONVEYOR

55K, CTN FLOW RACK $25K, TOTE TRAYS $50k

$300,000

CONSULTING FEE/EXP - $51,000

TOTAL COST - $351,000

ROI – 3.7 MONTHS

SEAL GLUE/TAPE

CARTONTOP

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JD GRAY ASSOCIATESCONTRACT INDUSTRIAL ENGINEERS

PACED ASSEMBLY WITH LIVE STORAGE AND RETRIEVAL CAROUSELS

ROI AND SKETCH OF PROPOSAL

SAVINGS POTENTIAL

AUTOMATION CONCEPT

Robotic concept operating a synchronous precision indexing conveyor and LSRS for a work-in-process buffer on each of the four shifts. Typical Savings: Forty-eight packaging operator savings = 96,000 hours @ $12 per hour = $1,152,000. Additional 16 operator reduction than used on the flow rack/semi-automation concept or 32,000 hours @ $12 per hour or $384,000. A total of $1,536,000 in direct labor savings. In addition, there would be a 100% increase in output.

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JD GRAY ASSOCIATESCONTRACT INDUSTRIAL ENGINEERS

AUTOMATION CONCEPT

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FORM GLUE/TAPE

CARTONBOTTOM

MACHINE

P/P ROBOT P/P ROBOT

Automatic load of pre counted

container stacks into

LSRS anytime not unloading

FIXTURIZED UPRIGHT CARTONS (ROTARY)SYNCHRONOUS PRECISION INDEXING CONVEYOR

SEAL GLUE/TAPE

CARTONTOP

MACHINE

RETURN-ON-INVESTMENT

TYPICAL SAVINGS - $1,536,000 -----------------------------------

EQUIPMENT BUDGET COST –TOTES TRAYS 50K, TOTE INSERTS

10K, SYNCH CONVEYOR 55K, AUTO BOX 150K, P/P 150K, I/E

220K, LSRS 170K…$805,000

CONSULTING FEE/EXP - $51,000

TOTAL COST - $856,000

ROI – 6.7 MONTHS

PICK & PACK TOP &

BOTTOM

FLATCARTON

FEED MAGAZINEAND FULL CARTON

UNLOADER

BOTTOMS

LSRS

I/E ROBOT

TOPS

LSRS

I/E ROBOT

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