Hussmann Material Handling Case Study
Key Technology
- Hytrol 26-CRPT Power-Rotated Turntable and 25-LREZ Heavy Duty Accumulating Conveyor
- Blue Arc Engineering Base Tipper, Canopy Flipper, Dolly Transfer, and Canopy Gantry
- Allen Bradley PLC and Parker CTC Human-Machine Interface (HMI)
- Zimmerman Bridge Cranes
- Ergonomic Partners and Zimmerman Manual operator Manipulators
Business Challenges
- Hussmann wanted to replace their existing food display cooler assembly line with three sub-assembly lines that would converge onto a main line
- The management team requested a constantly moving, paced assembly line utilizing enhanced automation and ergonomics
- The challenge to the BMH team was accommodating the large size, flimsy material strengths, and wide variety of product dimensions and weights in the 1.5 Million sq. ft. facility
Results
- BMH's solution produces 100 display cases in 9 hours, an improvement over the old system that processed 100 cases in 10 hours
- The number of assembly operators required has been reduced from 110 to 75
Case Study Video- Script
Since 1906, Hussmann has been inspiring solutions by helping retailers preserve and display fresh foods. Hussmann serves a wide variety of customers involved in the global cold chain. These include supermarkets, mass merchants, warehouse clubs, convenience stores, drug stores and foodservice establishments.
Hussmann is part of the climate control technology sector of Ingersoll Rand. They are a world leader in merchandising equipment and refrigeration systems.
Hussmann's headquarters and primary manufacturing is located in Bridgeton, MO, about 15 miles West of St. Louis.
Line 7 starts consists of three main sections, material delivery, subassembly, and main assembly.
In concepting this system, Hussmann wanted to replace the existing assembly line with 3 subassembly lines that converge onto a main assembly line. They requested a constantly moving, paced assembly line utilizing enhanced automation and ergonomics. The biggest challenge was accommodating the wide variety of product dimensions and weights.
The original system produced 100 cases in a 10 hour shift with 110 operators. The new system produces 100 cases in 9 hours, with only 75 operators. Increasing their production efficiency while reducing labor by 35 operators.
Line 7 starts with material delivery to the 3 subassembly lines feeding the main assembly line. Two upstream Makron molding machines produce Bases, Backs, and Canopies, which are automatically placed in custom pallets by a pre-existing vacuum gantry system.
The custom pallets are conveyed onto a Hytrol 26-CRPT Power Rotated Turntable, which rotates the pallet 90 degrees and discharges onto an extended pop-up drag chain transfer. The drag chain conveyor then advances the pallet until centered over the Hytrol model 25-LREZ Heavy Duty Accumulating Conveyor, where it is lowered onto the takeaway conveyor for subassembly accumulation.
Looking downstream toward the subassembly area, bases are accumulated on the right, and Backs and Canopies are intermittently accumulated on the left. Above the accumulation conveyors, an overhead power and free conveyor system accumulates and delivers frames for back subassembly. You can see the accumulated carriers waiting to descend and deliver frames to the subassembly area.
The two back panels shown on the right and the frames shown on the left, are manually carried to the adjacent back subassembly line, where operators assemble the pieces. The canopy panel is then manually carried to the canopy subassembly line.
Back subassembly showing the assembly of frames to back panels.
Three subassembly lines converge onto the main assembly line. From top to bottom on the drawing, they consist of Base, Back , and Canopy subassembly
Bases are placed upside down and conveyed on Hytrol Model RB conveyor during subassembly. When completed, the bases are automatically flipped 180 degrees by the Blue Arc Base Tipper, and placed right side up on the parallel main assembly line. As the first component to reach the main assembly line, the case is now inducted into the constantly moving assembly process, paced at around 3 fpm.
Upon completion of subassembly, backs are manually lifted and flipped 90 degrees with a Zimmerman Vacuum manipulator. They are then conjoined inline with the bases, conveying down the main assembly line.
Canopies are delivered on the pallet accumulation conveyor, where operators manually place canopies on the adjacent subassembly line. The canopies are subassembled and conveyed into the Blue Arc Canopy Flipper, where they are automatically flipped 180 degrees, onto a parallel Hytrol Model TL for additional subassembly.
After a start-up, debug, and a few months of operating the system, the operations personnel found this automated component of the system to be more trouble than it was worth. Due to unforeseen interference with canopy wiring harnesses, operators tried to tape the wires down or bundle them in a bag, but they proved to be too problematic. Therefore, Hussmann decided to remove the canopy tipper and upstream cleated belt conveyor, reverting back to simple gravity roller conveyor and manual flipping of the canopies onto the downstream belt conveyor.
Upon completion of subassembly, the Blue Arc Canopy Gantry automatically transfers canopies onto 3 perpendicular Hytrol model RBI conveyors for delivery to the main assembly line.
The subassembled canopy is staged at a 9 foot elevation along the back side of the main assembly line.
An operator uses a Zimmerman vacuum manipulator to manually lift the canopy, flip it 180 degrees, and place it on top of the case moving down the main assembly line.
Refrigeration coil assemblies are subassembled around a push-cart track where different components are installed and sautered at each station.
After completing the subassembly loop, a subassembled refrigeration coil is manually lifted from the cart, using the coil manipulator, and placed in a case on the main assembly line.
A concrete pit was constructed to provide operrators ergonomic access to the cases for electronic testing.
At the end of the main assembly line, an embedded pop-up drag chain transfer lifts the case and conveys it perpendicularly to another drag chain conveyor for final assembly of the case end panels.
An operator on each side of the case, uses a pedestal mounted Gorbel Easy Arm, fitted with a custom vacuum lifting device to manually lift and position end panels for installation.
After installing the end panels, the case is conveyed onto the Blue Arc Dolly Transfer, where an operator positions a dolly before lowering the finished case for transport.
Controls were provdided by the Controls House, a local controls engineering firm.
The project was broken into two phases to accommodate the transition from the existing production line. Phase 1 consisted of the material delivery conveyor, which accumulated bases, backs, canopies, and frames.
Phase 2 consisted of all subassembly and main assembly downstream of material delivery.
Craig Lorio provided dedicated site supervision and greatly contributed to the success of this project. His organization, adaptability, and can-do attitude proved invaluable throughout this dynamic project. He also effectively managed onsite contractor meetings, offsite testing of custom equipment, and project finances.
Broad range of activities and equipment: Excavation/Masonry, Overhead Power and Free, Hytrol, BAE, Zimmerman, Ergonomic Partners Phased start up helped ease the transition and keep us on schedule Two project meetings per week with the customer helped us balance the install with other facility changes
Flexibility of design and execution throughout the project. Well executed site supervision / PM Quick and efficient startup/debug Collaboration with various suppliers Innovative technology and automation
Contact Us
1-800-772-0464
