Creform BST Style AGV and Flexible Kitting Cart Eliminates Line-Side Assembly Storage


Aerospace sub-assembly parts supplier utilizes Creform kitting carts to minimize assembly space while increasing assembly efficiencies.



A manufacturer of aerospace sub-assemblies was utilizing its assembly production floor for storing working inventories of parts and components.  This created a variety of hidden costs.  The cost of floor space was certainly one expense, but one of the most significant costs was the time it took assemblers to walk back and forth in order to obtain parts and components to build the assemblies.  Eliminating these secondary costs was the challenge.  Creform Corporation, Greer, SC. responded.  The company determined the answer was simple.  Providing all inventory to the assemblers on a just-in-time basis without them having to leave their workstations.



Creform engineered a system of a fleet of flexible kitting carts and AGV tuggers that present sequenced kits of parts to each of its assembly stations.  The core of the system is a supermarket storage area located in the company's warehouse.  Here, parts and components are pulled in sequence and placed in the compartmented kitting carts that were built using the Creform System of pipe and joints.  Each cart holds either one product kit for single assignments or in some cases, multiple kits for small batch production.  Presenting the specific kits for production offers efficiencies for manufacturing because associates get exactly what they need, when they need it and no more.  The cart used (shown), features eight horizontal compartments and two shelves, all with plastic floors and sides for damage-free parts handling and easy load/unload in the ergonomic strike zone.  The other side of the cart has pegboard to hang components and supplies on for quick identification and retrieval. The cart handles parts and components with or without packaging while also accommodating small totes.  It has a 29" x 40" footprint and a 500lb capacity. 



There are several other cart designs in the fleet, custom built for specific sized parts and quantities with weight capacities up to 850lb. To differentiate between departments there are four different pipe colors used in the cart fleet. 



The carts are mobilized using Creform BST style AGV NSI model tuggers.  These individual tuggers follow a predetermined magnetic tape guide path on the factory floor, drive under a stationary kitting cart, extend a tow pin into a BST hitch plate beneath the cart then deliver it to a predetermined workstation.  It then lowers its tow pin, leaving the cart for the assembler while driving off to pick up an empty kitting cart, delivering it back to the supermarket staging area for reloading.  Just a small group of these NSI AGVs are delivering and returning a fleet of several dozen kitting carts. 



Creform chose its NSI AGV models because each unit can manage up to 50 courses, 128 commands each with RFID readers for command initiation.  These units, combined with the Creform Traffic Management System deliver the sequenced carts on a just-in-time schedule keeping assemblers supplied with parts without any production floor storage.



In addition, the AGVs all have Creform's opportunity charging feature so they can operate for a full shift without the need for battery changing.  For safety, they have audible and flashing light warnings plus non-contact laser bumpers with 16 view sets giving them a safety 2 category rating.  The other advantage of the system is its flexibility.  Being a sub-assembly component supplier requires that these carts be periodically modified.  The Creform System of pipe and joints allows this to be accomplished quickly with little waste.  And, if the AGV routes need to change, the only requirement is to remove the magnetic tape, install a new route, command tapes and RFID tags plus update the traffic management system.



The manufacturer has increased its assembly efficiency and added additional workstations in the space previously used for storage and inventory.  The AGV system is reliable and keeps the pipeline filled and assemblers in their places.  As an added benefit, the saved floor space allows for future expansion should the need arise.



Online at www.creform.com. Creform is a registered trademark of Yazaki Kako Corporation and Creform Corporation




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