The one-aisle mini
load buffer stages work-in-process sub-assemblies
and finished products.
Conveyors deliver parts for assembly from the mini
load to ergonomic Use-Point-Manager workstations.
System
Manufacturing operation for latch, handle, plate, and opening/locking mechanisms for emergency exit doors.
Thousands of combinations of different mechanisms, handles, plates and finishes are assembled to customer order.
Standard products and custom products are produced on a JIT basis for general contractors and distributors.
Mini load use-point
manager stores purchased and manufactured component parts,
subassemblies, and finished-in-process products.
Seven assembly workstations are located at the side of
the mini load use point
manager.
Completed orders are packed at an eighth workstation.
Four lines prepare subassemblies, which feed to the mini
load conveyor loop.
Stations that deliver and return material from manufacturing processes, such as polishing machines, are on the side opposite assembly operations.
Two sizes of shipping boxes are automatically erected and manually loaded with the product and ancillary equipment (screw kits, instruction sheets and templates).
Boxes are conveyed through a taper and automatically labeled with contents, P.O. number and delivery address.
All inventory tracking, job scheduling, performance tracking,
and weigh-count checking, is controlled by the system computer,
which is online to the corporate host computer.
Results
Occupies 50% of floor space required for the previous operation.
Inventory reduced 33-66%, depending on the commodity class.
Cycle time reduced 50 to 75%, depending on the model.
Worker productivity increased 57%.
Efficient production for high-variety, low-quantity, make-to-order products.
Virtually 100% sustained accuracy exempts material in
the mini load from annual
physical inventory.
The one-aisle 
