B-8051 Ingersol Rand - Heubel Shaw · 2015-10-08 · system, Ingersoll-Rand minimized both space...
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T BRIEFINGS benchmark www.Remstar.com To consolidate an inventory of small, high-value parts for the manufacturer of large centrifugal compressors – and also to stock small replacement parts shipped to customers – the Ingersoll-Rand Company, recently erected four 24.6-foot tall Remstar Shuttle Vertical Lift Modules (VLMs). The heavy- duty VLMs allowed the plant to eliminate the static racks that formerly stored the high-value parts. The investment reduced storage floor space from 2000 to 242 square feet and eliminated security fencing. The fully enclosed VLMs can be locked shut and their controls dis- abled, although such measures are rarely undertaken at the plant. By combining production and service parts in one automated system, Ingersoll-Rand minimized both space and materials handling personnel requirements. The com- pany is one of the country's leading manufacturers of centrifugal com- pressors used for air separation and for chemical, petrochemical, and refinery processes. Compressors fabricated in Mayfield range from 250 hp to 10,000 hp. “Floor space is at a premium in our facility, and the area freed by the Remstar high density storage Shuttle VLMs permitted the Assembly Department to expand compressor sub-processing and thereby boost manufacturing effi- ciency,” reported Darlene Valentine, Manager, Materials and Traffic for the plant. “The Shuttle system has also increased picking productivity by 25% per line item picked/ restocked, reduced reclamations from mispicks by 80%, and cut parts shrinkage/misplacement to a degree not yet fully documented.” Valentine reported that the VLMs were installed in only two weeks. “The Shuttle VLMs have been reliable from their installation through their usage,” she added. Each of the enclosed Shuttle units have 75 trays, 49” wide x 32” deep, to accommodate parts totaling no more than 400 pounds. Tray-to-tray spacing was custom- selected and ranges from 4 to 29 inches to maximize storage efficiency. The Shuttle system contains pinions, finished impellers, thrust collars, rotor bolts, valves, and other items. Parts are retrieved via keypad by any of the plant’s materials handlers. Tray and The Shuttle VLM system reduced the floor space requirements from 2000 to 242 sq. feet and delivers all material to a ergonomically efficient workstation. Ingersoll-Rand Co., Mayfield, KY SITE Manufacturer combines production and service parts APPLICATION Four Shuttle™ Vertical Lift Modules EQUIPMENT Reduced errors by 80%, increased productivity by 25% while saving 75% floor space SUMMARY Manufacturer Consolidates Multiple Areas To Save 75% Floor Space While Increasing Productivity 25% & Reducing Errors By 80%
Transcript of B-8051 Ingersol Rand - Heubel Shaw · 2015-10-08 · system, Ingersoll-Rand minimized both space...
T
BRIEFINGSbenchmark
www.Rem
sta
r.com
To consolidate an inventory of small, high-value parts for themanufacturer of large centrifugalcompressors – and also to stocksmall replacement parts shipped tocustomers – the Ingersoll-RandCompany, recently erected four 24.6-foot tall Remstar Shuttle VerticalLift Modules (VLMs). The heavy-duty VLMs allowed the plant toeliminate the static racks that formerly stored the high-value parts.
The investment reduced storagefloor space from 2000 to 242 squarefeet and eliminated security fencing.The fully enclosed VLMs can belocked shut and their controls dis-abled, although such measures arerarely undertaken at the plant.
By combining production andservice parts in one automated system, Ingersoll-Rand minimized
both space and materials handlingpersonnel requirements. The com-pany is one of the country's leadingmanufacturers of centrifugal com-pressors used for air separation andfor chemical, petrochemical, andrefinery processes. Compressorsfabricated in Mayfield range from250 hp to 10,000 hp.
“Floor space is at a premium inour facility, and the area freed bythe Remstar high density storageShuttle VLMs permitted theAssembly Department to expandcompressor sub-processing andthereby boost manufacturing effi-ciency,” reported Darlene Valentine,Manager, Materials and Traffic forthe plant. “The Shuttle system hasalso increased picking productivityby 25% per line item picked/restocked, reduced reclamations
from mispicks by 80%, and cut partsshrinkage/misplacement to a degreenot yet fully documented.”
Valentine reported that the VLMswere installed in only two weeks.“The Shuttle VLMs have beenreliable from their installationthrough their usage,” she added.
Each of the enclosed Shuttleunits have 75 trays, 49” wide x 32”deep, to accommodate parts totalingno more than 400 pounds. Tray-to-tray spacing was custom-selected and ranges from 4 to 29inches to maximize storage efficiency.
The Shuttle system contains pinions, finished impellers, thrustcollars, rotor bolts, valves, and other items. Parts are retrieved via keypad by any of the plant’s materials handlers. Tray and
The Shuttle VLM system reduced the floor space requirements from 2000 to 242 sq.feet and delivers all material to a ergonomically efficient workstation.
Ingersoll-Rand Co.,Mayfield, KY
SITE
Manufacturer combinesproduction and serviceparts
APPLICATION
Four Shuttle™ Vertical LiftModules
EQUIPMENT
Reduced errors by 80%,increased productivity by25% while saving 75%floor space
SUMMARY
ManufacturerConsolidates
Multiple Areas ToSave 75% Floor
Space WhileIncreasing
Productivity 25%& Reducing
Errors By 80%
The materials handler places replacementparts in a carton for shipment to a customer.
Operator uses the operator friendly keypad to enter a tray number for retrieving or putting away a part.
compartment codes are printed on bills-of-material generated by the facility's ManufacturingOperating System.
“Tray presentation never takeslonger than a few seconds, a greattime savings compared to formerpicking by manlift,” Valentine said.“Parts are removed from trays at
waist height, minimizing lifting.” Retrieved production parts are
either hand-carried or carted imme-diately to Assembly, or they are carried or carted to a sub-assemblykitting/packing table and combinedwith parts pulled from flow and pallet racks. Customer replacement
parts also proceed from the VLMs tothe packing table for packaging andshipping.
Conveyor in front of theRemstar VLMs delivers incomingparts from Receiving. Accompany-ing paperwork contains the putawaylocation codes for part numbersalready assigned to the Shuttles. Fornew part numbers (P/Ns), the mate-rials handler in the area assigns thelocation codes. Picking and put-away normally take place simultane-ously.
Parts stored on the modules aregenerally grouped by families, suchas all thrust collars on one Shuttleunit. Parts are removed from theirshipping cartons prior to putawayfor easier viewing and retrieving.Some parts remain in the manufac-turers’ packaging, others are storedunprotected, such as finishedimpellers lying exposed on foampadding. Shielding from dust anddirt is a major advantage of theenclosed VLMs.
“Because of the Shuttle VLMequipment’s tight control of P/Ns
and storage locations, the units arebeing employed as a beta test areafor a planned conversion to barcod-ed part number tracking throughoutthe plant,” Valentine concluded.
Four 20-foot tall Remstar Shuttle™ VLMs at the large centrifugal compressor plant delivers parts to operator.
“Tray presentation never
takes longer than a few
seconds, a great time
savings compared to
picking by manlift.”
Remstar International Inc.
41 Eisenhower Drive, Westbrook, ME 04092800-639-5805
www.Remstar.com [email protected]
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© Remstar International Inc Equal Opportunity Employer
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