The Half Ton Conundrum

In the fast-paced world of auto manufacturing, efficiency is paramount. Every minute saved in the production process translates to increased productivity and ultimately, a competitive edge. Recognizing this imperative, one of the leading auto parts suppliers turned to Alba Manufacturing and their integration partner, Ingalls Conveyors, Inc., for a solution to streamline their operations. The result? A groundbreaking palletizing line that revolutionized their manufacturing process.

The challenge presented to Alba Manufacturing was formidable: processing a large volume of bumper covers efficiently with limited resources. The auto manufacturer required multiple processing stations but only had two de-stacker systems available. Additionally, there was the intricate task of rotating the large modules 90 degrees to ensure the order picker could access them in the correct orientation. It was clear that a conventional approach would not suffice.

Alba Manufacturing, renowned for its expertise in material handling solutions, rose to the occasion. Collaborating closely with their integration partner, they devised a system tailored to the specific needs of the auto parts supplier.

The cornerstone of the solution was Alba's innovative metal module de-stackers, which efficiently distributed the modules to the various workstations which utilized a series of Thru-Frame Chain Transfers and Thru-Frame/Thru-Drive Side Transfers. This design allowed the manufacturer to maximize the utilization of their existing resources while maintaining optimal workflow.

However, the true game-changer was the incorporation of a lift and rotate unit into the conveyor system. This unit enabled seamless orientation adjustments of the modules and eliminated the ergonomic challenges associated with manual rotation. Previously, operators had struggled to maneuver the large and heavy modules weighing up to 1,000 pounds on ball transfer tables, leading to inefficiencies and potential safety hazards. With the lift and rotate units, this cumbersome task was reduced to the simple push of a button and significantly enhanced operational efficiency and worker satisfaction.

Moreover, Alba's commitment to innovation was evident by incorporating value-added features such as the 24VDC Itoh Denki drive roller design on the Thru-Drive Side/Thru-Frame Transfer. This was necessary because there wasn’t any room for a standard 460-volt motor due to interfacing with two (2) Thru-Frame Transfers. Wiring of photo eyes, proximity switches, solenoid valves, and motors to a junction box was included on both the lift and rotate units and transfers. These features not only enhanced the performance and versatility of the system but also underscored Alba's dedication to delivering solutions that exceeded customer expectations.

The benefits of the collaboration between Alba Manufacturing and Ingalls Conveyors, Inc. were profound. By leveraging their expertise and innovative technologies, they transformed the auto parts supplier's manufacturing process, enabling them to meet the demands of a rapidly evolving industry with unparalleled efficiency.

Value Added Feature(s)