Conveyor systems are usually built for durability and an extended working life. With consideration for certain factors like the type of product and usage rates, conveyors can run for years and generate excellent return-on-investment. However, ROI diminishes and the conveyor starts costing more money than it’s worth if it’s extended too long.  Systems can be the lifeblood of warehouse operations, so relying on an old one can begin to cost more than replacing it.

There are signs to look for when you suspect your system is affecting your overall efficiency and bottom line.

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American Greetings, the largest greeting card company in the world, with a mission that includes the desire to make the world “a more thoughtful and caring place,” had an issue with its aging conveyor system. The company creates a variety of greeting cards and other products in its massive Osceola, Arkansas facility (which has more than 10 miles of conveyors and occupies a space around the size of 57 football fields).

The plant runs 24 hours, so finding a way to upgrade without reducing production was a challenge.

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From throughput requirements to building expansions, you want to be ready for your company’s future. Sometimes these changes take place over longer periods of time, and sometimes they’re lightning-fast—your products and throughput can change from season to season based on shifting customer demands, market conditions, explosive growth, and other factors outside your control.

Sometimes conveyors are incorrectly called inflexible since they are often installed on a floor level, but their benefits can ultimately create greater versatility by optimizing an operation and creating more efficient material flow. Let’s look at 3 ways conveyors increase operational flexibility: Read the rest of this entry »

In Lean Manufacturing, less is more.

A Lean operation’s ultimate goal is to eliminate waste in a system, which it achieves by creating flexibility and disposing of overproduction. Lean environments sometimes shy away from using powered conveyors in their operations, but when correctly applied, automation propels Lean Manufacturing goals—not hinders them. It’s the “secret sauce” of excellent lean manufacturing and warehousing operations.

In a true Lean environment, the customer is paramount. In other words, you need to consider what the customer wants to pay for at every point in your production. The automated solutions of today can help your Lean Manufacturing operation in three significant ways. Read the rest of this entry »

A video overview of vertical conveying solutions

An excellent way to move products vertically in a distribution environment is through spiral conveyors. You can move materials between levels (pick modules, mezzanines, multi-story buildings) using several methods, but when it comes to carton or tote loads that are so common in order picking applications, the choice tends to be between spiral conveyors, incline conveyors, and package handling lifts.

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When you look at your next live roller conveyor system, it’s smart to look at new advances. Hytrol’s e24 conveyor is one of the most important new product introductions in many years. It’s difficult to understate how this conveyor can enhance operations, but here is a quick summary of the advantages.

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Sortation systems in distribution is application driven – typically we are talking about order fulfillment (retail, wave pre-sorting, inbound putaway sorts), shipping (end of line carrier sortation, ship to stores), and returns. Traditional sweep sorters, cross-belt, narrow slat & shoe, or belt sorters are often thought of as “for the big guys” in large operations. SpanTech’s new TranSorter is  different, and it’s rolling out at Modex 2012. A sneak peek video below:

The TranSorter is built for hard to sort items, such as fragile items that require different handling. It’s good for ultra-lightweight items, poly bags, etc.  It’s scalable, flexible, and affordable due to truly modular design, a world of layout possibilities, and competitive pricing. It can also deploy quickly, with 6-8 week delivery times and a couple days installation time. If you’re planning to attend Modex, check it out.

Conveyors are exceptional in their productivity enhancement for manufacturing and distribution operations, but they need attention – and not just from your maintenance group. Everyone involved with them should be aware of the safety and performance issues involved. Here are five practices for happy conveying…

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The amount on your purchase invoice isn’t the last time you’ll pay for that conveyor, but those ongoing costs of operations can be dramatically reduced by making good decisions at the point of purchase. If a conveyor is correctly specified and designed for future use, costs over time can be slashed.

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We just finished adding 3 new Conveyor White Papers, including helpful information on Critical Product and Load Orientation, a Picking, Packing and Loading Application Matrix, and Sortation System Controls Comparisons table.

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