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Asian Paints Material Handling Case Study

Key Technologies

Business Challenges

  • Following the completion of the four-phase project, Asian Paints (APL) wants to be the largest paint plant in the world with a final production capacity of 400,000 kl/year.
  • Asian Paints wanted to distribute directly to their dealers from its new 130-acre facility in Rohtak (close to New Delhi).
  • ASAP and BMH were tasked to design a packaged materials and finished goods ASRS with conveyors and lifts that would allow Asian Paints to expand in four phases over the next 4-5 years.
  • The new system had to handle an anticipated volume of 264 pallets per hour, fully automated and controlled using a WCS system.

Results

  • ASAP and BMH were able to successfully help Asian Paints implement phase 1 full production within 3-4 months of project handover. Phase 2 is scheduled to go live by April 2012.
  • Asian Paints is positioned to grow order volume (phase 2-4) without adding additional labor.
  • Stock accuracy, productivity, and throughputs have increased dramatically.

Multi-Media

Photos

Automated Storage and Retrieval (AS/RS) 01 Automated Storage and Retrieval (AS/RS) 01
Automated Storage and Retrieval (AS/RS) 02 Automated Storage and Retrieval (AS/RS) 02
Automated Storage and Retrieval (AS/RS) 03 Automated Storage and Retrieval (AS/RS) 03
Automated Storage and Retrieval (AS/RS) 04 Automated Storage and Retrieval (AS/RS) 04
Automated Storage and Retrieval (AS/RS) 05 Automated Storage and Retrieval (AS/RS) 05
Packaging Materials Denesting and Depalletizing Packaging Materials Denesting and Depalletizing
Finished Goods Pallet Stacker/Destacker Finished Goods Pallet Stacker/Destacker
Finished Goods Robotic Palletizing Inbound and Outbound Conveyor 01Finished Goods Robotic Palletizing Inbound and Outbound Conveyor 01
Finished Goods Robotic Palletizing Inbound and Outbound Conveyor 02Finished Goods Robotic Palletizing Inbound and Outbound Conveyor 02
Finished Goods Robotic Palletizing Inbound and Outbound Conveyor 03Finished Goods Robotic Palletizing Inbound and Outbound Conveyor 03
Finished Goods Robotic Palletizing of Paint Buckets 01 Finished Goods Robotic Palletizing of Paint Buckets 01
Finished Goods Robotic Palletizing of Boxes 01 Finished Goods Robotic Palletizing of Boxes 01
Finished Goods Robotic Palletizing of Boxes 02 Finished Goods Robotic Palletizing of Boxes 02
Finished Goods Robotic Palletizing of Boxes 03 Finished Goods Robotic Palletizing of Boxes 03
In-Line ScaleIn-Line Scale
Finished Goods Vertical Lifts to Bridge 01 Finished Goods Vertical Lifts to Bridge 01
Finished Goods Vertical Lifts to Bridge 02 Finished Goods Vertical Lifts to Bridge 02
Finished Goods Inbound Bridge Conveyor 01 Finished Goods Inbound Bridge Conveyor 01
Finished Goods Inbound Bridge Conveyor 02 Finished Goods Inbound Bridge Conveyor 02
Finished Goods Automated Storage and Retrival (AS/RS) Upper Level Inbound ConveyorFinished Goods Automated Storage and Retrival (AS/RS) Upper Level Inbound Conveyor
Finished Goods Automated Storage and Retrival(AS/RS) Lower Level Outbound Conveyor 01Finished Goods Automated Storage and Retrival(AS/RS) Lower Level Outbound Conveyor01
Finished Goods Automated Storage and Retrival(AS/RS) Infeed SpurFinished Goods Automated Storage and Retrival(AS/RS) Infeed Spur
Finished Goods Automated Storage and Retrival(AS/RS) Lower Level Outbound Conveyor 02Finished Goods Automated Storage and Retrival(AS/RS) Lower Level Outbound Conveyor 02
Finished Goods Warehouse Inbound Conveyor Finished Goods Warehouse Inbound Conveyor
Finished Goods Outbound Transfer Car Finished Goods Outbound Transfer Car
Finished Goods Warehouse Outbound Conveyor Finished Goods Warehouse Outbound Conveyor
Finished Goods Pallet Flow Stageing Finished Goods Pallet Flow Stageing
Finished Goods Outbound Pallet Finished Goods Outbound Pallet
Finished Goods Outbound Floor Staging for Shipping Finished Goods Outbound Floor Staging for Shipping
APaint Fill Process 01Paint Fill Process 01
Paint Fill Process 02Paint Fill Process 02
Paint Fill Process 03Paint Fill Process 03
Asian Paints Rohtak Project Team Asian Paints Rohtak Project Team
Mike Patterson and Matt Adams on Site Mike Patterson and Matt Adams on Site
Neeraj Kumar, Site Support Engineer Neeraj Kumar, Site Support Engineer
Bill Bastian II and Mitch Smith Site Visit Bill Bastian II and Mitch Smith Site Visit
Project Team - Area Wildlife Project Team - Area Wildlife

Renderings

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