The challenge
Delay in the assembly
Intergas aimed to improve efficiency in both logistics and assembly. They planned to pre-pick a full day's worth of stock in logistics, then place it at the assembly line. This way, assembly workers could immediately start assembling. The concept revolved around ensuring that when a cart was empty, a fully stocked cart was ready, already filled by logistics. In the current situation, the stock was not adjusted for a full day's work; instead, an entire box of components was delivered to the assembly spot, which was actually unnecessary.
A clear separation of logistics and assembly
Additionally, in the current situation, cables were delivered messily in a box. Assembly workers had to untangle them one by one, consuming much time and slowing down the production process. Hence, a clear separation between logistics and assembly was crucial: logistics handled the logistics work, allowing assembly workers to focus solely on assembly. The goal was to minimize ancillary activities such as gathering parts for assembly workers.
Finally, Intergas utilizes a broad range of reach trucks and forklifts for which the cart needs to be suitable.
The solution
Organized layout thanks to forklift order picking carts
The solution is an forklift order picking cart, on which the logistics department brings a full day's worth of stock to the assembly line. This cart presents all the necessary parts in an organized manner and makes them easily accessible. Thanks to pre-unpacking and sorting, assembly only needs to pick up and assemble the components.
Previously, all products were simply placed on one level, but Multitube advised using a unique storage bin for each product and placing them in the picking cart. This created an organized layout with multiple structured bins.
Intergas' Picking Cart Designed for Efficient Transport with Various Vehicles
To ensure minimal movement of the picking cart along the assembly line, it is equipped with wheels. Additionally, it can be moved using electric pallet trucks, reach trucks, and order-picking trucks that are in use at Intergas. No new vehicles need to be purchased because the positioning and width of the fork pockets are designed to be compatible with all these vehicles. These fork pockets are equipped with powerful magnets for secure transport.
Furthermore, extra space has been created in the cart so that it can be expanded at any time when new products are added. With this solution, Intergas is now able to assemble 18 pieces x 4 levels = 72 pieces per day.
What are the benefits
Integrating forklift order picking carts into their processes has resulted in the following benefits:
- Improvement in both the logistics and assembly processes
- Reduction of inventory on the line
- Reduced downtime and increased control in assembly due to a constant and accessible inventory
- An organized logistics process as they take on the complete logistics tasks
- Ergonomic operation
TESTIMONIAL
"The professionalism of Multitube is excellent; they think along well with your issue/question."
Efficient collaboration and the deployment of various specialties have led to the optimal end result. Quick responses and a proactive approach have advanced the project progress, resulting in positive feedback about the final product. Both production and logistics are experiencing a positive solution, with the delivery of high-quality products. The improvement in picking parts at the correct height is a significant advancement for the employees.
Production Proces Engineer
Optimize your processes with forklift order picking carts
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