Efficiently balancing the workflow between work cells and zones that require different hourly or daily demands can significantly increase productivity and throughput in manufacturing and assembly operations.
One way to achieve these efficiencies is through the use of the buffering technique. Buffering temporarily holds items in storage while they are being moved from one location to another or from one process to another and releases them when required.
What makes buffering different from simple storage? By temporarily holding items in an organized, high density and accessible location between operations, buffering allows differing processes to run at their optimum efficiencies. It also eliminates process bottlenecks that occur when pieces stack up in a queue waiting for the next operation.
Buffering is a commonly applied technique in manufacturing and assembly operations where automated and manual processes work at varying rates on different shifts and days. It is also a common practice in balancing the incoming receipt of materials with production and shipping requirements, or to store semi-finished goods for later finish work to meet market demand.
Adding Automated Storage and Retrieval Systems
When traditional rack and shelving storage is replaced by automated storage and retrieval systems, such as horizontal and vertical carousels and Vertical Lift Modules (VLMs), the efficiencies of buffering become even more significant.
These automated systems allow organizations to reduce wasted floor space while providing total visibility, fast and efficient Just In Time (JIT) delivery of items. Integrated inventory management software can be used to monitor consumption of materials in a workstation or cell and can automatically signal the buffer storage devices when buffered inventory is required and to where. Processes can be manual, semi-automatic or automated depending on specific facility requirements and Return On Investment (ROI) calculations.
Automated buffering systems include technologies such as carousels and VLMs. Vertical carousels consist of shelves that rotate up or down via the shortest path, delivering items to an ergonomically positioned pick window. The VLM is an enclosed system of vertically arranged trays, an extraction platform and a series of computerized controls that delivers items to an ergonomically positioned workstation. The VLM automatically locates and retrieves stored items with a push of a button or a scan of a bar code. Several VLMs can be placed side-by-side or back-to-back to form a compact and efficient automated storage and retrieval system.
The vertical design of both of these systems maximizes the use of overhead space and can recover up to 85% of the floor space required for traditional shelving systems. This recovered space can be used for more value added operations. Because items are delivered to the operator, the walk and search time necessary with rack and shelving systems is eliminated, significantly improving retrieval productivity.
Horizontal carousels are designed with an oval track with rotating bins containing shelves that deliver items to the operator. They are often used in integrated workstations called a pod. A pod configuration allows an operator to pick from one active carousel while the others are pre-positioning to be picked the moment the operator is ready. Horizontal carousels can be equipped with pick-to-light technologies to indicate the active carousel, shelf level and quantity of items to pick for added throughput and accuracy. They can reduce floor space requirements by up to 60% and increase throughput by up to 600% while reducing labor requirements by up to 2/3.
All of these automated storage and retrieval systems can be integrated with software systems for added efficiencies in assuring items are available when and where necessary to optimize manufacturing or assembly processes. The result is an overall optimization in productivity and a reduction in operating costs.
KardexRemstar Inc., a company of the Kardex AG Group is a leading provider of automated storage and retrieval systems for manufacturing, distribution, warehousing, office and institutions. For information about the KardexRemstar automated storage and retrieval systems, call 800-639-5805 or visit the KardexRemstar web site at www.KardexRemstar.com.