10 DIY Projects for the Innovative Warehouse. Track 5 Session 7

Transcription

1 10 DIY Projects for the Innovative Warehouse Track 5 Session 7

2 Coleman Johns W. W. Grainger Engineering Manager Phone:

3 Deb Rice Dematic Solution Development Manager Phone: Josh Larsen Dematic Account Manager Phone:

4 Abstract If necessity is the mother of invention, this is the window into the maternity ward. It is often the owners of automation that invent the most creative homegrown solutions to enhance the utility, performance and serviceability of their systems. In this showand-tell, we will get an overview of 10 ownerdeveloped ideas that are field proven, effective and worth your consideration ranging from safety to system throughput. Take good notes! 4

5 Agenda 10 DIY Ideas Idea Overview Why we did this? Cost Photos/Explain Key Takeaways Questions Open Discussion 5

6 1. Anti-Gridlock Beacon Issue: Delay in cycle time due to cadence or flow issues Solution: Install a proximity sensor that will allow a 5second blockage that will illuminate a beacon to team members of a near full capacity condition. Benefit: Allows operations to shift team members to the appropriate locations to continue processing work before induction ceases and anti-gridlock begins recirculation process. Cost: This system was implemented for about $500 CJ 6

7 1. Anti-Gridlock Beacon CJ 7

8 2. The Lost Scanners Issue: Symbol Scanners from were coming up missing. Solution: RFID tags were added to the Symbol units. The RFID reader was interlocked with the shipping and empty carton system to shut off the induct when a tag was detected. Benefit: The amount of scanner replacement costs were reduce to $0 with an ROI of 5 months. Cost: This system was implemented for about $5,000. Deb 8

9 2. The Lost Scanners RFID Reader Beacon and Annunciator Deb 9

10 2. The Lost Scanners Schematic for RFID Reader 12vdc output to 12vdc relay control of conveyor Deb 10

11 3. RS200 Tracking Stand Issue: Time to change out transition bed and track the belt on the RS200 (sliding shoe sorter) was too long. Solution: Developed a stand with power connections to allow for belt tracking and run-in prior to installation. Benefit: Transition bed can now be changed out in 50% less time with minimal adjustments after installation. Cost: This system was implemented for about $2,500 Josh 11

12 3. RS200 Tracking Stand Josh 12

13 4. Gate Open Alert Issue: Gate remains in the up position which impedes the HU flow to DTL. Solution: Install a proximity sensor which sounds a horn if left in the open position more than 20 seconds. Benefit: Allows passage through without having potential error of leaving the gate in the open position. Cost: This system was implemented for about $300 CJ 13

14 4. Gate Open Alert CJ 14

15 5. On Board Cameras Issue: Safety and time issues to recover from faults and recover load errors on the SRM (Storage and Retrieval Machines). Solution: Implemented remote camera system with LED. Benefit: Allows for the view of forks and loads remotely. Errors can be recovered without entering aisle promoting safety. Allows for later viewing of incidents for implementation of corrective action. Cost: This system was implemented for about $2,500 Deb 15

16 5. On Board Cameras Deb 16

17 6. Kotecki s Recycling Chute Issue: When it s -20F in Wisconsin and you want to recycle a soup can or (more likely) a beer bottle, you open the door to the garage to toss it in the recycling bin and $35 worth of heat goes out the door. Solution: A PVC pipe angled through the wall Benefit: Virtually eliminates heat loss due to soup can tossing and, if you are cooking at the time, prevents cooking goo from getting on your garage door knob. Cost: This system was implemented for about $25 Josh 17

18 6. Kotecki s Recycling Chute Josh 18

19 6. Kotecki s Recycling Chute Caulk seams PVC pipe (Bologna cut) Rubber hinge Plexiglass flapper INSIDE Small Weight GARAGE Josh 19

20 7. Mobile Package Counter Issue: Needed the ability to install a package counter in various points of the system that was not designed to have a PPE (Package Present Eye) Solution: Designed method where all was needed was 120v power supply to count packages at any point of HU flow. Benefit: Easy install and can be relocated for studies at a moments notice. Cost: This system was implemented for about $300 CJ 20

21 7. Mobile Package Counter CJ 21

22 8. Spare Parts Where You Need Them Issue: Spare Parts are not always nearby the equipment for which they are intended to support. This can cause unnecessarily technician travel time and extended equipment downtime. Solution: Strategically place spare parts closer to the intended equipment or build replacement kits that can be strategically placed. Benefit: Reduced technician travel time and equipment downtime. Cost: Initial time in designing strategic areas and kit solutions. Deb 22

23 8. Spare Parts Where You Need Them Strategic Storage spare parts are typically located in a single area which may not be conducive to where they are needed. Develop multiple parts storage areas closer to use point. Parts Kit Storage Maintenance Deb 23

24 8. Spare Parts Where You Need Them Place spare parts where they are needed (at the point of failure) with tooling and instructions for replacement. Deb 24

25 9. Stretch Wrap Mods Issue: Pallet jacks have trouble accessing the wrapper due to the turntable being elevated. Solution: Lowered the floor in the area to allow universal access to the machine from three sides. Benefit: Increased the efficiency and safety off the team by allowing pallet jack access to the wrapper without ramps. Cost: This system was implemented maintenance with minimal additional cost. Josh 25

26 9. Stretch Wrap Mods Josh 26

27 10. HU Induction Scales Issue: Overweight packages on the conveyor creating safety issues and flow problems. Solution: Fabricated and installed scales at each induction point to mitigate risk of overweight product on conveyance system. Benefit: Reduces risk of team members lifting an overweight item and also reduces damage or jams on conveyance system due to weight constraints. Cost: This system was implemented for about $100 CJ 27

28 10. HU Induction Scales CJ 28

29 11. AGVS Drive Tools Issue: Safety and time to remove the AGVS drives do to weight and location. Solution: Fabricated specialty tools to assist techs with removal and repair. Benefit: Increased the efficiency and safety of the technicians. Cost: This system was implemented for about $1,500 Deb 29

30 11. AGVS Drive Tools Deb 30

31 12. E-stop Markers Issue: Team members were having trouble locating the closest e-stop to stop or restart system following a stop. Solution: Install a simple marker visible at eye level to allow quick location of closest box. Benefit: Reduced the time for team members to locate the closest station. Cost: This system was implemented at a cost of $15 per station. Josh 31

32 12. E-stop Markers Josh 32

33 13. Fire System Shunt Issue: In Case of a fire the conveyor system would continue running. Solution: Add a shunt relay to the control cabinets to all conveyor operations to cease in case of fire emergency. Benefit: Eliminates the need to endanger human life to shutdown individual cabinets in case of fire. Cost: This system was implemented for about $1000 CJ 33

34 13. Fire System Shunt Relay CJ 34

35 14. What Does Safe Look Like? Issue: Safety is a big part of our daily operations and adherence is a must. We have signs in critical areas, however, it does not guarantee that employees interpret the desired safe behavior. Solution: Provide visuals of safe behavior along with PPE equipment where they are needed. Benefit: Consistent interpretation of safe behavior Cost: Initial time in developing the visuals and cost for PPE areas. Deb 35

36 14. What Does Safe Look Like? What seems obvious may not be Deb 36

37 14. What Does Safe Look Like? A picture is worth a million words Deb 37

38 14. What Does Safe Look Like? What you need right where you need it 38

39 15. Enhanced Sound Deadening Issue: If your material handling or automation is in an otherwise lab or clean environment, with an office atmosphere, you may need a higher level of quiet. Solution: Acoustic Panels hung under (or around) equipment Benefit: Greatly reduces sound reflection when the room is bright. (tile floors, hard ceiling, etc). Reduces employee fatigue and need for hearing protection (validate with db meter) Cost: $60/4ft of panel + chain + labor Josh 39

40 15. Enhanced Sound Deadening Hang from chain with S hooks to allow access for maintenance Josh 40

41 16. Charging Complete LED Issue: Batteries on Personnel Carriers were not complete charging and creating a short battery life span. This was also creating operational issue due to equipment failing during operation. Solution: Install contactor and LED to inform operator that the unit was full charged and ready for use. Benefit: Allows battery to fully charge, creates longer asset life and no team member downtime. Cost: This system was implemented for about $100 CJ 41

42 16. Charging Complete LED CJ 42

43 Key Takeaways There are many simple and low cost DIY project for all aspects of the material handling system and warehouse. Consider safety, efficiency, and complexity of solution for all DIY projects. Consult with OEM for modifications that may alter the operation or controls prior to implementing. Be sure to acknowledge great implemented employee ideas and their results consider a reward program. Josh 43

44 Questions?