Top Hat Cart Delivery System
A fortune 500 Company wanted a better way to deliver smaller components to the line as well as move palletized product to key areas in the plant. The other aspect of this project is that they wanted to deliver the carts to the line and have the line personnel work off the cart. We came up with a solution where they could do both depending on their needs at that particular moment. We designed and implemented a 6 Wheel Top Hat & Cart delivery system. We produced a cart that can fit a 48 x 48 inch pallet when needed and then was able to incorporate a Top Hat with shelves so they can move the smaller parts and bins to the line. What is significant about this is that when the carts are in a train, they track one after the other. When disconnected, the line worker can manipulate the cart easily into their area to work off the cart. This has been able to reduce WIP off the floor and create a replenishment system. When the cart is empty the material handler comes by and drops off a newly stocked cart and picks up the empty. This project has increased productivity by 40% to 45%.
Ergonomic Work Station & Delivery Trailers
These trailers were designed for a major appliance manufacturer. They wanted the ability to deliver parts for their appliances to the line. Not only that, when the trailer was dropped off, the line workers used the trailer as a work station. As you can see in the picture, the lever in the center of the trailer allows the deck of the trailer to rotate. By having this feature, the line worker never has to reach over to grab a bin which decreases the chance of straining their back. Everything is very ergonomic for the worker & has greatly reduced Workman’s Compensation Claims. Also, the shelving is removable. You will notice fork-pockets at the bottom of the shelving unit and at the top you will notice pegs at the 4 corners that allow the shelving units to be stackable. This increases floor space and sets up an efficient staging area when the Supermarket is ready to load the bins on the shelving units.
Customized 6 Wheel Carts for OEM Muffler Company
This was an intricate and complicated cart we designed for an OEM Muffler manufacturer. This company had multiple work cells that built mufflers for German car companies. They are going through a Lean transformation and wanted to eliminate pallets of product at each cell. Each cell had 4 to 6 pallets sitting at each cell. We designed a cart that can either be staged at their “Supermarket” and bring it to the line or replenish the carts when it is at the line. They wanted to have 2 hours worth of parts and components at each cell. By building this cart, we were able to eliminate 4 pallets plus a rack that held fasteners, etc….. By doing this, they improved the efficiency and increased the space available at each cell. We also saved them 42% in WIP on the floor.