Assembly Efficiency Solutions

Assembly Efficiency Solutions: A major GPS Component company wanted to improve the way they deliver their delicate electronic components to the clean room assembly area.  They wanted to move two types of containers; plastic bins with GPS chips and mobile carts holding micro phish film.  We were able to satisfy their goals by constructing 5 Trailers w/ shelves and 2 Low Boy Trailers with ramps to roll the mobile carts easily on and off of the trailer.  To move these trailers we determined how many trailers they wanted to move at one time.  From there we provided 2 tuggers that have the capacity to pull 5000 lbs. each. 
With this system, we streamlined their process to get the components to the line and improved their efficiency by over 60%.

Replenishment System to Move 5x More Product:

 We worked closely with a tire manufacturer to help them design and improve the way they were distributing their product line throughout the plant with our custom industrial trailers.  Due to the fact that they had many different size tires coming off the lines, we needed to surmise how big the deck of the trailers needed to be in order to move “X” number of tires per trailer.  Once we came up with that number, we had to make sure that the tires were contained and secure during transportation.  We accomplished this by making removable sides so the tires could be easily loaded.  We also made the sides high enough based on the number of tires that had to be transported per each trip.  With the removable sides, our customer was able to load from any side depending which direction they approached the line.

With providing them 10 custom trailers and 2 electric tuggers, we were able to increase efficiency and productivity by 40% as well as reducing their forklift fleet by 3.

Paper Mill Lean Solution

4,000 lbs. Capacity with Reverse Steer: We had the opportunity to work with a fortune 100 company to help them transport 2,000 lbs. bags of minerals from storage to their processing plant to be broken down and then delivered to shipping.  The hurdle was that they had to pull the train of 3 trailers weighing 12,000 lbs. up an 8% grade ramp.  In order to accomplish this we had to provide a tugger powerful enough to pull this kind of weight.  The other obstacle was the lack of room to turn the train around. 

Solution: We provided six 4,000 lbs. capacity trailers with reverse steer capability so they didn’t have to make a 180° turn.  They would disconnect from one end and re-connect on the other end and proceed to pull the train.  Along with that, we equipped them with a 40,000 lbs. pull capacity propane tugger to give them enough power to make it up the ramp without bogging down the motor.  By doing this, they eliminated all the forklifts in the plant and were able to move 6 times more per load compared to a forklift.

2000 lbs. Capacity Carts with Sides : A major wholesale food club company wanted to be able to move soft drinks, food products, and merchandise from their distribution center across the parking lot to their warehouse. They wanted to be able to move a number of product at once. We accomplished this by providing 2000 lbs. capacity carts with sides to contain the product. The sides on one of the carts are removable and the other cart has doors that open up completely in order to unload and load product. To move these carts we provided a PAV (Power Assist Vehicle) to tow the product. With this solution, they are able to move 4 times the product instead of with a forklift.

Power Transformer Manufacturer:

This company wanted to be able to eliminate forklifts and increase the number of transformers that they were able to move to and from the line. By doing this, we provided them with two 5 Ton Trailers that is going to move 4 transformers at a time. This will increase their efficiency by 75% and save over $10,000 per year leasing the forklifts. They will also be able to reallocate the forklift operator in a another area. Visit the MHS Lean Solution Examples page for more products ideas and solutions.

Mobile 2 Bin Line Replenishment System Efficiency Increase

In this project we worked with an electronic components company and increased the amount of product getting to their production line by 45%.  We did this by creating a “Supermarket” or central staging area in specific location in the facility.  From there we created a 2 Bin system by having a material handler replenish the line with components when the line needed them at a particular time.  The material handler would deliver the full bin and pick up the empty to be refilled.  In this project they decided to  use 1 tugger and 5 trailers with shelving to deliver components 5 times the amount then the way they previously did, which was by pallet and fork lift.  They were also able to get inventory off the floor and use the inventory on an as need basis. Visit the Lean Solutions Page for more examples.

Paper Mill Uses Custom Trailers to Conform to OSHA Standards

To conform to OSHA, MHS supplied this client with four, 15,000 lb. capacity trailers, each equipped with Electric Brakes. Our trailers offered two advantages, 1) increased safety for the employees, and 2) allowed the mill to transport eight, 7000 lb. paper rolls at one time, eliminating 4 to 5 costly forklifts.  Visit the MHS Lean Solution Examples page for more products ideas and solutions. 

Fiberglass Fabricator Uses Tugger and Trailer System to Solve Efficiency Issues

This fabricator utilized both our tug and trailer systems to transport multiple units of unfinished and finished product from building to building during various stages of manufacturing. This not only condensed there work force, but also allowed them to increase production by adding two product lines.   Visit the MHS Lean Solution Examples page for more lean product examples.