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Multi-level shuttle system increases space utilisation and operational efficiency
Comfortable, stylish, safe and durable seating is a significant element of the complete driving experience in any car, but never more so than in the case of high-end vehicles such as those produced by Jaguar Land Rover. Entrusted with the contract for delivering these essential items to the JLR plants in the UK is the Coventry factory of Lear Corporation, a world leader in this field
W
hen Lear moved to new 22,000m2 premises, prompted by increasing
sales of JLR models around the world, initially, the internal logistics systems used at the old factory continued, with components being picked manually and delivered on trolleys to the assembly lines, requiring large numbers of staff and wide aisles. Seat sets are produced in hundreds of different specifications, and the JLR factories operate on just-in-time principles, requiring suppliers to integrate closely with production schedules. In order to meet JLR’s requirements, Lear replaced the manual process with an automated system that takes components from the racking to the production area with minimal manual handling and also replenishes stock, freeing floor space for production and improving productivity, safety and efficiency.
GEBBHARDT EUROPEAN CONVEYOR SYSTEMS AWARDED CONTRACT Nottingham-based Gebbhardt European Conveyor Systems was awarded the contract for this project, consisting of an automated storage and retrieval system (ASRS), extensive mezzanines and high- level racking with space for over 20,000 trays in two sizes. The ASRS equipment consists of 14
multi-level shuttles (MLS) in four aisles and a single mini-load crane in a central fifth aisle, which is used for slower- moving product lines. Each shuttle can access 1,200 tray locations and complete 50 in-and-out cycles per hour. The mini-load crane can access 4,300 tray locations and complete 70 in-and-out tray cycles per hour. This design has a potential throughput of 770 trays/hour to four picking stations where the required selection of items for each order is assembled for onward despatch to the production area.
S6 MARCH 2018 | MATERIALS HANDLING & LOGISTICS
COMPACT AND FAST-MOVING The shuttles and crane are compact and fast-moving allowing Lear to have the maximum amount of storage while also achieving the throughput required. As the shuttles and crane are able to handle the large and small tray types, all products can be stored anywhere in the overall system. Maintenance mezzanines have been incorporated throughout the racking, which also allows picking to continue manually if required. The system has been designed to
deliver parts in sequence to the assembly area on the ground floor, correlating to the JLR production schedule. The shuttles and crane pick the required items according to instructions from the warehouse control system (WCS) and delivery them to the pick stations where the sets of components are sequenced before being delivered by conveyor to the production area for assembly. Following a completed picking sequence at a picking station, the tote or carton used is delivered by conveyor to a specific drop point within the assembly area on the ground floor, up to 92 metres from the pick station. This conveyor is designed to accept a wide variety of plastic totes or cardboard cartons, handle at least 600 items/hour and automatically return empty containers to the ASRS mezzanine. The ASRS system also enables up to
185 trays/hour to be delivered from an incoming product induction area into the racking. Material induction is located on the ground floor and is connected via an elevator to the main conveyor loop. Two induction stations are operated, where barcode labels are applied to trays and carton s that include package identification, package code, package quantity and tray identification. Packages are also checked for dimensions and weight. Maximum acceptable weight is 55kg.
WAREHOUSE CONTROL SYSTEM The Gebhardt warehouse control system controls all high level function in the automation, such as the routing of the trays on the ASRS and the conveyor systems, the location of the trays in the ASRS, the linking of products with the tray identification, and it also manages the operator (HMI) screens on the system.
GEBHARDT European Conveyor Systems Limited T: 0115 987 4363
www.gebhardt-group.com
/ MATERIALSHANDLINGLOGISTICS
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