Norpak Case Study: Dramatic Decrease In Product Damage
CUSTOMER OBJECTIVES:
- Reduce/eliminate product damage
- Eliminate worker injuries caused by repetitive beding, straining, and stretching thus lowering compensation claims
- Streamline manufacturing process
- Improve productivity
THE PROBLEM:
A major manufacturer of plumbing fixtures used wheel carts to move greenware product throughout their production areas prior to final firing and shipping. The manual handling involved on moving and placing the unfired porselain pieces resulted in a high level of product damage. Repetitive strain injuries caused by the constant bending and stretching involved in the operation were unacceptable. The process was also slow.
THE SOLUTION:
Norpak Handling offered a solution involving zoned accumulation conveyor to carry product from station to station throughout the assembly area. A conveyorized smart car is then used to transfer completed assemblies to a series of accumulation lines prior to entry into the kiln for final firing. All accumulation conveyors included in the system are Hytrol ABEZ style with adjustable zone length and programmable dwell at all workstations.
THE RESULT:
- Production rate increase of 60%
- Dramatic decrease in product damage resulting in almost total elimination of product re-work costs.
- Steadily decreasing incidence of task related injuries
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