Assembly Line Conveyor System Integration & Execution
Appliance Manufacturing
Pictured: Overhead structural steel installation in progress to support elevated conveyance for assembly line system.
SilMan provided a custom assembly line conveyor solution to integrate new equipment and controls with an existing manufacturing material handling system, including structural steel installation for elevated conveyance and maintenance catwalk.
PROJECT SCOPE
System Design and Integration, Engineering, Structural, Project Management, Mechanical Installation, Electrical Installation, Controls Design & Programming
INDUSTRY
Manufacturing
LOCATION
Midwestern United States
Conveyor System Integration & Execution
Home Appliance Manufacturing
SilMan Industries was contracted by a leading home appliance manufacturer to design an assembly line material handling solution to provide added speed and efficiency in the transfer of finished goods from production to inventory. The project was executed by SilMan’s Material Handling System Integration team, drawing from their in-house design, engineering, and installation resources.
This turnkey project was designed by SilMan to be executed simultaneously with daily operations. Thanks to detailed planning between SilMan and the project owner, shutdown periods and weekend work were strategically undertaken to minimize interruptions.
The solution calls for the creation of a new line and modification of an existing line to divide the main flow of crates into two lanes through the final segment of assembly.
Additionally, the expanded overhead conveyance system included the removal of an existing escalator-style vertical lift to be replaced with an inclined belt conveyor to accommodate the speed of the new configuration.
Notably, the onsite work was completed in the summer of 2020. This plant was one of the few home appliance manufacturers that continued operations throughout the global pandemic.
The SilMan team performed all onsite work, including structural steel, mechanical, electrical, and controls.
Improved Throughput and Efficiency
Since the design creates two parallel conveyance lines where there was previously one, the new arrangement effectively doubles the rate of products transferred from the factory to the warehouse. Moreover, newer equipment will decrease downtime for repair and maintenance in this section of the line.
The creation of a new ceiling conveyance system is a key aspect of the design. In addition to expanding the volume of crates transferred to the warehouse, the overhead assembly provides a catwalk for maintenance personnel.
To accomplish these results, a temporary line was created to support ongoing operations during installation.
Results provided
- Increased overall throughput rates
- Improved efficiency of operations and upkeep
- No unscheduled downtime occurred during installation!
Speak to a key team member on this project
Meet David Rebata
For more information about this project or related topics, contact David by email or call directly at 510.409.6567.
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Self-Performance is Key to Success
SilMan integrators turn to our in-house Specialty Trade Services team to implement new technologies, equipment, and systems.
This multi-skilled service group supports all aspects of industrial operations, including mechanical, electrical, and facility improvements, to provide comprehensive, cost-effective solutions and minimize third-party sub-contractors.
Conveyor System Integration
Scope of Work
The scope of the package includes new structural steel for supporting ceiling conveyance, new incline belt conveyors, roller conveyors, controls, and modifications required for the integration of new and existing finished-boxed conveyance.
Three Project Phases
Phase one involves structural engineering by LECGI for overhead structures to support the new overhead conveyance and maintenance lane.
The structural work, performed by SilMan’s installation team, includes hangars, catwalks, platforms, and incline supports.
Phase 2 consists of building a parallel conveyance system for finished boxes from the assembly line to a newly created incline system to the modified ceiling conveyance system and routed to the warehouse.
The new lane includes an existing 90-degree Chain Driven Live Rolling Conveyor (CDLR), controls/hardware to accumulate trains of multiple units before advancing the products to the warehouse, via incline and ceiling conveyors.
Phase 3 provides for the reconfiguration of the existing lane.
The main feature of this aspect of the project is the removal of an esconveyor to be replaced by an inclined belt conveyor, supported by floor footings and newly installed reinforced ceiling hangars.
The new overhead line is identical to the existing ceiling conveyance, with the exception of new catwalks which allow crossover and maintenance on both lanes.
The new ceiling construction includes the installation of new conduit and wire runs.
A new diverter for damaged or incorrectly processed products was also provided. The operation is manually inspected and triggered by a team member, which directs the package to QC for remedial work and reinduction.
Home Appliance Assembly Line
Work in Progress
Photo credit: Troy Busse (SilMan Industries)
Appliance Manufacturing Material Handling Equipment
The mechanical equipment required for this project includes over 150+ linear feet of conveyor and 16 motors.
- Tapered Roller Curves,
- Horizontal Brake Meter Belt Conveyors,
- Belt over roller Incline Conveyor
- Conveyor Crossover
- CDLR Conveyor
- Roller Bed Belt over roller Incline Conveyor
- Photo eyes (40)
All conveyor equipment was provided by Roach Conveyors and Scanners from Cognex.
Conveyor System Electrical and Controls
The SilMan Controls Group designed and programmed the system per the project owner’s specs, installing Rockwell-Allen Bradley controls.
Specific control applications include photo eyes, merge, and accumulation zones.
Specialized skills deployed
Mechanical and Electrical Engineering
- Design
- Procurement
- Project Management
Structural Construction
- Structural steel (bolted)
- Ceiling hangars
- Floor supports
- Fabrication of platforms, decking, and guards
- Modification to existing structures
Mechanical Installation
- Millwright
- Pipefitters
- Conveyors
- Commission equipment
Electrical Installation
- Panel
- Power
- Devices
- Controls
- Commission equipment
90-degree Chain Driven Live Rolling Conveyor (CDLR)
Conveyor System Integration Team
Key Project Contributors
The accomplishments realized on this project is the result of excellent performance and communication by several key team members:
Todd Sadler: Project Management
Eric Bickford: Engineering, Project Management
David Birmingham: Engineering, Project Execution
Troy Busse: Mechanical Installation
Kevin Jackson and the SilMan Controls Group: Controls
David Rebata: Account Management
Midsouth and Midwest Industrial Sectors
SilMan continues to expand geographic service areas
SilMan Industries is no stranger to serving Midwest and Mid-South industrial concerns.
They established their first regional office in Tupelo, Mississippi in 2010 when the company was contracted to de-commission the NUMMI auto production line in Fremont, California, and relocate the assembly and conveyance equipment to Toyota’s Blue Springs, Mississippi facility.
Other projects completed in the region include automotive forge-press installation for Kobe Aluminum (Bowling Green, Ky.), multi-site line modifications for FedEx Ground, and cooperage manufacturing material handling systems for distillers Brown-Forman and Speyside, and McGinnis Wood Products.
About the Company
SilMan Industries (previously SilMan Construction) is based in San Leandro, Calif., with Engineering and Field Operations offices in Tupelo, Miss. The firm provides integrated turnkey solutions in the Industrial, Manufacturing, Distribution, and Public Works sectors.
Notably, in 2010 SilMan Industries was contracted to dismantle and remove the NUMMI assembly line in Fremont, Calif., transport the equipment, and reinstall the system in Blue Spring, Miss., establishing Toyota Motor Manufacturing Mississippi (TMMMS). This high-visibility project ignited the company’s meteoric growth, laying the foundation for SilMan’s national service area.
For more information, please visit www.silmanindustries.com/about.
