Flexeserve, a renowned company in the hot-holding and food-to-go solutions industry, has taken a significant step towards optimising their operations and increasing throughputs. With a growing demand for their products and services, Flexeserve sought an automated production and material handling solution that would enhance efficiency, improve ergonomics, and reduce cycle times. LAC, a trusted provider of automation solutions, rose to the challenge and delivered a tailor-made solution consisting of two mechanised production lines equipped with an inline automated pallet conveyor system.
Before the implementation of the automated solution, Flexeserve faced numerous challenges in their assembly process, leading to decreased efficiency and production rates. Manual handling of products, reliance on pallet trucks for movement between operators, and the repetitive nature of tasks resulted in time-consuming operations. Operators had to perform strenuous bending and stretching movements, which further reduced efficiency. Additionally, the nonsequential operations disrupted the flow of products, causing an increase in overall cycle time. Waiting times between operations added to the decrease in operator productivity and production rates. The primary objective was to streamline operations, minimise waiting times, improve production rates, and establish a continuous flow in the assembly line.
LAC’s solution successfully addressed the challenges faced by Flexeserve, revolutionising their production lines. The custom-designed solution incorporated a pallet loading ramp, height-adjustable workstations, and buffer stations to ensure a smooth and independent progression of products through the assembly line. The height-adjustable workstations, operated by automated controls, allowed operators to easily adjust their working heights and utilise a work complete button to signal task completion. Buffer stations strategically placed within the system minimised operator wait times, while the unload station facilitated manual offloading after final assembly. With safety measures in place, the CE certified system accommodated different pallet types. Integration of a scissor lift further enhanced the efficiency of the production lines, achieving an impressive throughput of 60 pallets per 8-hour shift, surpassing the capabilities of manual operations. Overall, the project successfully improved productivity and efficiency in the assembly line, fulfilling the desired objectives.
The solution LAC implemented comprised of a pallet conveyor-based production line, loading and unloading stations, customised and height-adjustable workstations with automated controls, buffer sections, a Hymo Scissor Lift, and PLC & HMI based controls. This comprehensive approach ensured a seamless and efficient flow of products throughout the assembly process.
The benefits of LAC’s automated solution have been significant for Flexeserve. The streamlined production lines, height-adjustable workstations, and buffer stations have not only improved efficiency but also reduced cycle times and minimised operator fatigue. The remarkable throughput achieved by the system surpasses what could be achieved through manual operations, enhancing overall productivity. As a result, Flexeserve now possesses a highly efficient assembly line, enabling them to deliver their solutions and services faster to meet the increasing demands of their customers.
In conclusion, the collaboration between Flexeserve and LAC has resulted in a successful implementation of bespoke pallet conveying, revolutionising the company’s production lines. The automated solution has streamlined operations, reduced cycle times, improved efficiency, and minimised operator fatigue.
With these enhancements, Flexeserve is well-equipped to meet the growing demands of their customers and continue their position as industry leaders in hot-holding and food-to-go solutions.
Comments are closed.