Product category:
Benches, work stations, platforms, lifts, parts storage and cabinets
News Release from: Bito Storage Systems | Subject: Kitting Bay system - assembly
Edited by the Manufacturingtalk Editorial
Team on 05 July 2006
Kitting bay system handles variety of
containers
Kitting bay system at engine plant handles a mixture of pallets, metal stillages and cartons or plastics containers - for front picking - with empty return and replenishment from the rear.
To increase the storage density for a greater number of components in parts kitting operations, BITO Storage Systems have developed a new solution, which is already in operation for one major UK automotive manufacturer The new Kitting Bay solution can handle a mixture of pallets, metal stillages and cartons or plastics containers
This article was originally published on Manufacturingtalk on 11 Oct 2006 at 8.00am (UK)
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It is designed to allow picking from the front, with pick by light if desired, with empty return and replenishment from the rear.
Premium car manufacturer BMW have already deployed the new solution at their Hams Hall engine plant, near Birmingham, UK, delivering greater capacity from a restricted area and increased efficiency for a relatively low investment cost.
The parts kitting area already existed at the site, but a rapid rise in the number of engine variants led to a problem of capacity.
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A number of solutions were considered, including a fully automated store, yet BITO was able to develop a Kitting Bay solution with BMW which delivered the required extra capacity from the restricted area for less than 10% of the cost of full automation, with less risk, in record time.
"We were approached by BMW to come up with a solution which gave them fast kitting in restricted space and incorporated empties returned to the rear for removal," stated Edward Hutchison of BITO Storage Systems.
"We designed a special unit based on sliding block puzzle principle and were able to provide a prototype of the agreed design in just two weeks." The design and prototype were agreed, including testing with Euro pallets and BMW's Gitter boxes, essentially a metal stillage for components.
The transfer of picking systems was planned to be carried out over a single weekend.
The BITO element was installed in three phases, the first within a very short timescale.
This required good planning, close co-operation between various subcontractors and excellent communication.
According to BMW, the old system was working on the Friday and the new one by Monday morning with no loss of production or stock.
Each Kitting Bay has capacity for two pallets or stillages for picking, each presented on a low level ball table for easy movement to a central 'empties' position.
When a pallet is picked to empty staff can move it sideways on the ball table with very little effort, allowing a reserve pallet to move from its live storage position behind.
Above this low level storage is a gravity powered carton live storage level, allowing for the handling of containers holding smaller or slower moving items.
This is easily reachable from the ground floor level due to the low height of the ball table below, allowing for picking from two levels.
This was one of BMW's key requirements.
Above this second level, standard pallet storage allows for buffer stock to be held at the rear of the Kitting Bays, ready for quick and easy replenishment.
Each Kitting Bay has capacity for two pallets or stillages for picking, each with one replacement behind, plus six KLT Euro containers.
BITO has designed an ingenious array of physical safety devices including non return locks and one way saloon doors, making sure that pallets and stillages, which could weigh up to 600kg, cannot move backwards or sideways into the wrong location, even when they are leaned on by staff picking from the carton live storage above.
"This is an important health and safety consideration for the picking staff and reduces the risk of component stock damage," claimed Hutchison.
At the Hams Hall installation, there are now over 63 new Kitting Bays, arranged facing each other into picking aisles with replenishment from the rear.
Fork trucks are used to move full and empty pallets and stillages from the area, with specially designed pallet trucks loaded with containers for the carton live storage.
The picking aisles have excellent lighting, which creates a bright and integrated working environment, the lamps are supported by BITO structural beams that span the gangway and connect to the picking system uprights.
Picking aisles are served by Automated Guided Vehicles (AGVs), each collecting parts for one particular engine.
As BMW operate a 'batch of one' method of production, each load could be different although some parts are more common than others.
So as an AGV with engine block arrives at a picking area, staff are directed via a pick by light system mounted on the Kitting Bays.
Staff load each required component stored in their area, guided by a computer control system.
When their picking tasks are complete, the AGV is released to move on to the next area.
Once all components are loaded, the AGV will move to the production area where the engine is assembled.
Performance of the Kitting Bay solution in practice has been impressive.
Due to the clear layout and compact design, staff are more productive and travel less distance themselves, contributing to greater efficiency.
"Whether for space saving or efficiency, this new development will appeal to many manufacturers kitting for assembly, especially in the automotive industry," stated Hutchison.
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