Modular Automotive Systems (MAS), a division of Hollingsworth Logistics Group, provides front and rear fascia assemblies in sequence for an automotive OEM on a JIT basis. MAS's current assembly process begins with fascia outer shells being placed on carts equipped with protective cradles. The carts are manually moved through production cells where associates employ hand-held scanners that provide assembly component data instructing them which parts are to be assembled inside and outside each fascia. The final step is a QC station where the completed fascias are checked for proper assembly and functionality. They are then loaded in proper sequence on mobile racks and delivered to OEM assembly plants. The process is labor intensive and also requires a considerable amount of production floor space.
Christian Cantrell, Program Manager/Process Engineer, MAS, was looking for a new and better way to increase productivity and reduce the possibility of sequencing errors as well as the potential to damage the class A finish on the fascias.
Cantrell said, "We were familiar with carousel assembly systems, which we believed would be a better way to achieve our objectives, but also knew that to change over our assembly operations to this method could be cost prohibitive.
"Over the years we have been using the Creform System of plastic coated steel pipe and joints to create many of our material handling structures. We have had an excellent working relationship with them and they have helped us design and build a wide variety of racks, tables and carts. A few months ago we met to discuss our needs and options for creating a continuously moving assembly line. Several ideas were considered, including a paper clip shaped route and moving cart concept. However, they said this might not operate smoothly, so it was determined that a circular carousel system was our best option.
"Creform assured us that they could design and build an automated carousel to meet our needs using a combination of its pipe and joint system in tandem with its AGV units at a significantly lower cost than a traditional turnkey system. They came back to us quickly with a carousel system design that has eight stations and provides each associate with a pie shaped work zone that utilizes floor space in a more efficient manner."
The new carousel design employs a combination of eight carts built with Creform plastic coated 28 mm pipe and metal joints for flexibility should needs change. Each cart has a custom configured rack covered with protective material to hold the fascia components in place during assembly. The carts are held end to end by tongues and hitches and ride on a circular rail that is bolted in position on the floor. Each cart rides on four casters, two with grooved wheels that guide them on the rail.
The carousel is powered by a low-speed, Creform bolt-on style AGV unit attached under the lead cart. It travels at 0.05 MPH, (1.5 meters/minute), has a load capacity of 1,496 lb. (680 kg) and is powered by two TPPL AGM batteries. For safety, each cart has a wireless auto-stop key fob that will stop the entire carousel if needed.
For recharging, the batteries are rolled off the AGV on to a Creform cart with conveyors, eliminating the need to lift the batteries. Then they are plugged into a dual charger and when fully charged, will operate continuously for 18-24 hours before requiring recharging.
Each carousel station has a computer keyboard and screen mounted to a Creform built structure that easily fits in the center open space created by the carousel. This provides assembly associates with a complete sequence of the parts to be installed on each fascia. The system is capable of handling up to 250 part numbers. It is virtually impossible for a fascia to get out of sequence since they are only handled when being placed on or removed from the cart. In addition, the company reported that the likelihood of damage to a fascia's finish is extremely low because of the minimal handling by associates.
The pie shaped work areas created by the carousel design reduce the required floor space for each operator station by 50%. This helps keep the entire area from getting overcrowded while easily accommodating all the needed parts for assembly at each station.
Cantrell said, "Creform completed the task and had the first carousel installed and running in about eight weeks. In addition, they told us they could modify the carousels if required and add one to three additional carts in about seven to ten days. Our initial target was to handle 50 fascias in 47 minutes and the first carousel was able to do it in 36 minutes. We are still in the process of fine-tuning but we are more than satisfied with how well the system works.
"The best part is that each carousel cost about 15% of the total of just one traditional carousel unit. In addition, we are able to complete each assembly operation using fewer associates allowing us to reassign them to other value added tasks and operations."
The Creform System is used to create an array of material handling and efficiency enhancing devices, including push, special purpose and trailer carts, flow racks, roller conveyors, workstations and AGV/AGCs.
For more information contact:
Creform Corporation
P.O. Box 830
Greer, SC 29652-0830
800-839-8823
scsales@creform.com
www.creform.com