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Material Handling Information - Case Studies - Von Duprin
   
Case Studies - Industrial Products Application
Von Duprin
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Application
  • Von Duprin -- Indianapolis, IN.
  • Manufactures emergency exit door handles and latches for industrial applications.
Key Customer Benefits
  • Brings material to the operators; cuts cycle time by eliminating wait, walk, and search time.
  • Work-in-process inventory reduced 65%.
  • Operator productivity increased 57%.
  • Real-time inventory control with instantaneous reports to host computer.
  • Improves product quality.
  • Supports Just-In-Time delivery.
  • Allows make-to-order instead of make-to-inventory production.
Material Flow Requirements
  • Reduce inventory to a maximum five-day supply.
  • Streamline the manufacturing process.
  • Move materials between workstations instead of workers.
  • Move materials only once for each value-added operation.
  • Base production on make-to-order, rather than make-to-inventory.
Material Flow Hardware
  • One-aisle, dual-shuttle mini load with 2,218 storage locations.
  • Input/output roller conveyors.
  • Seven ergonomic use-point-manager assembly workstations.
Computer Control System
  • Real-time inventory control system linked to Von Duprin's host computer.
Material Flow Process

Input
  • Raw material, sub-assemblies, and small assembly components are placed in totes.
  • An operator identifies the tote material and quantity to the inventory control system as an expected receipt.
  • Conveyor delivers the tote to an input station, where the quantity is automatically verified by a scale before induction into the mini load for staging.
Output
  • Rack side conveyors deliver raw materials directly to the fabrication area.
  • Fabrication workers machine, polish, or plate components, then return the Work-in-Process (WIP) to the mini load for staging.
  • Assembly workers order parts as needed from terminals at their workstations.
  • The mini load retrieves totes containing subassemblies and finished components, sending them to a rack side conveyor for delivery to the workstation.
  • Workers complete the assembly process, sending the finished products to the mini load for staging prior to final packaging and shipping.
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