Material Handling Information - Labor Intensive Processes

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Daifuku America

Material Handling Information - Labor Intensive Processes

Ergonomics

Labor Intensive Processes

Overhead monorails at Sharp automatically deliver material to robotic assembly workstations.

Conveyors deliver parts for assembly from the mini load to ergonomic workstations at Von Duprin.

Problem

Long cycle times caused by complex, multi-task operations in non-assembly-line manufacturing.
Frequent Worker injuries and their related costs.
Lost time and reduced worker productivity.
Significant non-value added handling between processes.
Low job satisfaction, high employee turnover due to monotonous tasks.

Solution

For multi-task operations, consider de-coupling complex processes into single tasks along a small assembly line.
Reduce monotonous tasks and improve worker satisfaction by:

Using robotics to handle small component assembly tasks such as pickup, insert, and set-aside operations.
Eliminating non-value-added tasks wherever possible.

Automate delivery and takeaway of material using mini load, unit load, or high-speed box buffers, carousels, power-assist units, Automatic Guided Vehicles (AGV), Sorting Transfer Vehicles (STV), overhead monorails, or conveyors.
Use forklifts, power-assist units, Automatic Guided Vehicles (AGV), Sorting Transfer Vehicles (STV), overhead monorails, or conveyors to eliminate manual lifting and transport.
Develop and maintain comprehensive process documentation.
Implement dexterity exercise programs to reduce repetitive motion injuries.

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