Global Material Handling System Integrators
 
 

Asian Paints

 

Phase 1: Rohtak Automation Program

Asian Paints has set up its sixth largest decorative paint plant at Rohtak, Haryana. This state of the art paint plant is located at Industrial Model Town developed by Haryana State Infrastructure and Industrial Development Corporation. With a production capacity of 400 million liters of paint every year this plant is one of the largest in the world.
 

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asian-paints-system-illustration

Business Objectives

  • 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).
  • Bastian Software Solutions and Bastian Solutions 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.

Key Technologies

 

Results

Bastian Solutions was 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.

 
 

Photos

  • Automated Storage and Retrieval (AS/RS) 2
  • Paint Fill Process 4
  • Automated Storage and Retrieval (AS/RS) 5
  • Finished Goods Warehouse Outbound Conveyor
  • Finished Goods Robotic Palletizing Inbound and Outbound Conveyor 2
  • Finished Goods Robotic Palletizing Inbound and Outbound Conveyor
  • Asian Paints Outbound Warehouse
  • Finished Goods Robotic Palletizing of Boxes
  • Finished Goods Automated Storage and Retrival(AS/RS) Lower Level Outbound Conveyor
  • Finished Goods Robotic Palletizing Inbound and Outbound Conveyor 3
  • Finished Goods Automated Storage and Retrieval(AS/RS) Infeed Spur
  • Robotic Palletizing 2
  • In-Line Scale 2
  • Finished Goods Robotic Palletizing of Boxes
  • Finished Goods Automated Storage and Retrival (AS/RS) Upper Level Inbound Conveyor
  • Finished Goods Outbound Transfer Car
  • Mike Patterson and Matt Adams on Site
  • Finished Goods Outbound Floor Staging for Shipping
  • Finished Goods Outbound Pallet Flow Stageing
  • Finished Goods Pallet Stacker/Destacker
  • Automated Storage and Retrieval (AS/RS) view 3
  • Asian Paints Rohtak Project Team
  • Finished Goods Vertical Lifts to Bridge
  • Bridge Conveyor to Warehouse
  • Finished Goods Automated Storage and Retrival(AS/RS) Lower Level Outbound Conveyor

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