Introduction
Transforming an Outdoor Knife Manufacturer’s Assembly Line for Maximum Throughput and Compact Efficiency
When a well-known outdoor knife manufacturer wanted a more efficient assembly process for existing product manufacturing, they came to Bosch Rexroth distributor, Pacific Integrated Handling (PIH), with an idea for a compact assembly line with automated material push and takeaway.
To add to the challenge, due to the COVID-19 pandemic during the time of the build, the line needed to accommodate the current rules and regulations with operating in a COVID-sensitive environment and adapt as that landscape shifted. While this type of new manufacturing process idea was new and ambitious for their industry, PIH had all the digital tools, assembly technology partners, and in-house expertise needed to bring the manufacturer’s vision to life.
Challenges & Results
Challenge: Maximize a small warehouse footprint to increase the efficiency and ergonomics of an existing line with a compact assembly line.
Solution: Custom assembly line solution with aluminum extrusion ergonomic workstations and material flow racks, and a VarioFlow plus conveyor to feed and takeaway kitted build trays.
Results:
- 30% increase in throughput with a 53% reduced footprint
- Capability to run 30+ SKUs through the 4 stations
- Fewer material handlers needed to feed the line
- Higher flexibility to run multiple SKUs without operators needing completely new parts kits
Tech-Driven Collaboration
Designing Solutions in a Virtual Landscape
When PIH was approached with this project, the customer had a general idea of what they were looking to create but needed someone to put the vision together.
“Pacific Integrated Handling was founded on relationships and solutions, and we relish the opportunity to work alongside our manufacturing partners. Each customer process and solution set are a new and different challenge, and we were excited to help our customer bring this innovative process to life.” Deanna Peterson, VP Assembly Technology at Pacific Integrated Handling
Due to the COVID-19 environment, the initial meeting was virtual rather than in the plant itself, but that wasn’t a deterrent for experienced PIH technical sales, Jeff Brydson. A proficient user of Bosch Rexroth’s robust design software, MTpro, and 20-year veteran with Bosch Rexroth’s full assembly technology portfolio, Jeff was able to create the customer vision in MTpro as the customer gave feedback and input during the one-hour virtual meeting. Their vision included custom workstations, a conveyor to feed and takeaway “kitted build trays” and material flow racks. The meeting concluded with a 90% complete digital representation of the customer’s vision for them to take to management for concept and budget approval.
Elevating Ergonomics
Creating a Flexible and Comfortable Assembly Environment
With the vision realized, the engineering team at PIH went to work fine tuning the drawings and layout. This includes adding/defining custom materials like work tops, separation panels, Varioflow plus conveyor specifications, flow racks and material flow.
An additional consideration was the ergonomics of each of the stations. The assembly stations needed to be adaptable to provide the current worker with a comfortable work experience. This provided another opportunity for MTpro to shine. The Bosch Rexroth design tool includes ergonomic evaluation functions that allow the designer to represent workers of all sizes and visualize their ideal reach zones and cones of vision. This functionality helps ensure that the workstation layout fits your workforce and minimizes stress and work injury.
The layout’s compact design and attached assembly areas created a new challenge in the ergonomic work zones, adjustability.
A seated solution allows for the worker to adjust their sitting position with respect to the work area instead of the workstation height adjusting to the person. The addition of custom designed integrated footrests rounded out the ergonomic inclusions of this custom assembly line.
From Minutes to Seconds
Revolutionizing Knife Assembly Efficiency
Before this new process, the customer used to have one operator build the SKU from start to finish, taking anywhere from 80-120 minutes per kit, depending on complexity of build. Now with the assembly line style process, they can put out one SKU every 60-90 seconds.
The Industrial Manufacturing Engineer on the manufacturer’s team commented “By breaking down more complex builds into “bite-sized” steps within this new process, the SKUs that would normally take 6-8 minutes to build can be turned around in 90 seconds instead.”
With so many SKUs, changeover was major challenge for the customer, taking roughly 5-10 minutes depending on the specific SKUs involved in the transition. To streamline this process, the new process included parts trays that were organized by similar components and the quantities required for each SKU. This system allows for certain SKUs, even those from different families, to share common parts, which limits the changeover to just one or two stations that may involve colored hardware or additional components like clips or backspacers.
Transformative Collaboration
Redefining Efficiency in Outdoor Knife Manufacturing
When the project concluded, the collaboration between the outdoor knife manufacturer and PIH resulted in a transformative assembly line solution that not only stepped outside the box of standard processes in the industry, but also enhanced the efficiency and ergonomics in the manufacturing process. By leveraging advanced design tools like Bosch Rexroth’s MTpro, premium technology like Bosch Rexroth’s aluminum extrusion and Varioflow plus chain conveyor, and incorporating ergonomic considerations, PIH and the customer successfully created a flexible assembly line capable of accommodating over 30 SKUs while significantly reducing production times.
The shift from a traditional assembly method to a streamlined, assembly process has led to a remarkable 30% increase in throughput and a 53% reduction in footprint, demonstrating the effectiveness of innovative design in overcoming operational challenges. And by using the tray distribution on a Varioflow plus conveyor feeder line reduced the need for constant kit /parts replenishment and freeing up their material handlers for other processes.
Furthermore, the ability to adapt to COVID-19 regulations while maintaining productivity showcases the resilience, creative thinking, and adaptability of both the manufacturer and Pacific Integrated. With this new process in place, strategic partnership with Pacific Integrated Handling, and proven technology from Bosch Rexroth, the outdoor knife manufacturer is set up for success in a competitive market.
