Case Study: A Towering Achievement
Since their beginning in 1993, Tower Automotive has focused on acquiring three key components in order to become leaders in their field: cutting edge technical capabilities, the best in leadership, and a broad product range. Because of this, Tower has successfully made body structures, lower vehicle structures, suspension components and modules for nearly every major automobile manufacturer in the world, including BMW, DaimlerChrysler, Ford and General Motors. Tower Automotive currently has over 60 locations in 4 continents, employs over 12,000 people, and has annual revenues exceeding $2.5 billion. They contracted Bastian Material Handling to help them design a flagship distribution center for state-of-the-art assembly in Smyrna, Tennessee.
Challenge
- Install equipment between shifts so as not to compromise production schedule.
- Implement ergonomic part presentation for the operators in order to minimize injuries and fatigue while maintaining optimum build rate.
- Minimize Fork Truck traffic.
Bastian's Solution
- BMH co-engineered equipment with Tower, and shipped demonstration units off-site for trial. The complete assembly line included over 300 robots.
- All controls were pre-wired and shipped in modules to minimize installation time.
- BMH supplied over 140 Southworth Lift Tables and Lift and Tilt Tables, as well as manual “walkie” Big Joe lift equipment. As a result, operators were able to exchange empty containers on the lifts with full containers, without the need for fork trucks.
- 10 cells were implemented to help move 2500lb. racks of rails. This helped operators who were responsible for manually unloading these racks by loading the full racks into the line, and the empty racks out.
Results
- BMH’s solution reduced fork truck activity, thereby cutting expense and inefficiency.
- An ergonomic system was put in place which allowed Tower to reach their goal of minimizing reaching and repetitious movement while achieving maximum production.
- Production schedules were maintained as much construction and assembly took place off-site.
