When a well-known manufacturer of outdoor knives wanted a more efficient assembly process, the company turned to Pacific Integrated Handling (PIH), a Bosch Rexroth Certified Excellence partner based in Hayward, CA, with an idea for a compact assembly line with automated material delivery and takeaway. The line had to accommodate new regulations and adapt as the industry landscape shifted. While this type of project was new and ambitious for its industry, PIH leveraged modern design tools and assembly technology to bring the manufacturer’s vision to life.
When PIH was first approached, the knife maker only had a broad vision. PIH’s team translated that vision into a detailed, digital concept using Bosch Rexroth’s MTpro software in real time. As the customer shared feedback, PIH built that vision in MTpro, which included custom workstations, material flow racks, and a conveyor to move build trays. By the end of the one-hour session, the customer left with a 90 percent complete digital model to present for concept and budget approval.
With the vision realized, PIH fine-tuned the drawings and layout. Bosch Rexroth components included aluminum framing, work tops, separation panels, flow racks, and a VarioFlow plus conveyor.
An additional consideration was the ergonomics of each station. The stations had to be adaptable to provide each assembler with a comfortable work experience. The design software includes ergonomic evaluation functions that enable engineers to represent workers of all sizes and visualize their ideal reach zones and cones of vision. This functionality ensured that the workstation layout fit the manufacturer’s workforce and helped minimize the potential for muscle strain and work injury.
For example, at some stations, assemblers can work while seated. Workers can adjust their sitting position with respect to the work area, instead of the workstation height adjusting to the person. Custom-designed integrated footrests ensure worker comfort.
Efficient Assembly
Before the redesign, one operator would assemble a particular knife model from start to finish. The process took 8 to 12 minutes per kit, depending on the complexity of the model. After the redesign, the assembly process is broken down into “bite-sized” steps. Each worker handles a few operations in an assembly-line process. Now, the manufacturer can produce a knife every 60 to 90 seconds.
With so many SKUs, changeover was a challenge. The process could take 5 to 10 minutes, depending on the SKU. To streamline this process, the redesigned layout includes parts trays that are organized by similar components and the quantities required for each SKU. This system allows for certain SKUs, even those from different families, to share common parts. This limits changeover to just one or two stations that may involve colored hardware or additional components, such as clips or backspacers. Trays of parts are delivered to each workstation by the conveyor, which reduces the need for constant parts replenishment and frees up material handlers for other processes.
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The new assembly line can accommodate more than 30 SKUs while significantly reducing production times. The shift from a traditional assembly method to a streamlined process led to a 30 percent increase in throughput and a 53 percent reduction in footprint.
For more information on custom assembly lines, visit www.pacificintegrated.com.
For more information on conveyors, workstations and modular automation components, visit www.boschrexroth.com.
For more information on assembly line components, read these articles:
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