Challenge
A leading California-based manufacturer approached PIH with a unique production challenge: develop a manual conveyor system capable of moving large assembly carts around a continuous racetrack-style layout while maintaining smooth operator interaction, controlled product flow, and safe operation. The project came with an aggressive four-week delivery schedule and required a solution that did not exist as a standard off-the-shelf product.
Solution
PIH’s engineering team evaluated several possible approaches and determined that existing conveyor technologies were either overly complex, cost-prohibitive, or unable to meet the application’s requirements. Instead, the team developed a custom solution utilizing Bosch Rexroth VF90 conveyor components in a completely new way.
The system featured a manually operated racetrack conveyor that allowed large carts to seamlessly engage with custom-designed traveler pucks captured within the conveyor track. These proprietary travelers were engineered in-house and equipped with custom interfaces that securely connected to the carts, enabling smooth movement around the system with minimal operator effort.
To address a critical safety requirement, PIH also designed and manufactured a custom anti-reverse mechanism that prevented carts from being pulled backward, eliminating the risk of collisions between operators while maintaining uninterrupted forward flow.
Execution
With only four weeks from concept to delivery, PIH’s engineering, manufacturing, and supply chain teams worked in parallel to accelerate development. Custom components were designed, prototyped, tested, and refined in real time through multiple iterations.
The team leveraged its in-house machine shop to produce and modify parts rapidly, allowing design improvements to be implemented immediately without impacting project timelines.
At the same time, supply chain challenges required the team to identify alternative sourcing strategies and secure critical materials on expedited schedules to keep the project on track.
Results
With only four weeks from concept to delivery, PIH’s engineering, manufacturing, and supply chain teams worked in parallel to accelerate development. Custom components were designed, prototyped, tested, and refined in real time through multiple iterations.
The team leveraged its in-house machine shop to produce and modify parts rapidly, allowing design improvements to be implemented immediately without impacting project timelines.
At the same time, supply chain challenges required the team to identify alternative sourcing strategies and secure critical materials on expedited schedules to keep the project on track.
