IMI Cornelius, Inc. |
SIC: 3586
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Systems Integrator: Conveyor Solutions, Inc. (Schaumburg, IL)
Flexibility is the Key to Productivity
EZ Logic feature gives IMI Cornelius enhanced control
over materials flow and assembly process
Thanks
to a newly installed conveyor system, IMI Cornelius is maximizing production
efficiency of its Counter Electric soft drink dispenser at its Glendale Heights,
IL Focus Factory-and doing so in a cost-effective manner. The
simple-but-effective system integrates live roller conveyors, zero pressure
accumulation conveyors, spool transfers, a belt conveyor, and a chain-transfer
segment into one streamlined flow. But perhaps the real key is the built-in
EZ Logic capability, which effectively controls the flow of product throughout
the facility.
IMI Cornelius is a world leader in the manufacture
of beverage dispensing equipment and systems. The company's Glendale Heights
plant serves a truly global market. The dispensing equipment made here is
shipped not only throughout North America, but also to Latin America, Europe,
and Asia. To serve the demands of their global customer base, the company
needs a manufacturing system that is flexible, responsive, and highly efficient.
The new system delivers on all counts.
"The new installation has already given us a
number of important benefits," says Jeff Wright, the facility's director
of operations. "It has reduced product handling and increased throughput.
And at the same time, it's given us added control over product flow and
manufacturing rates."
A Flexible Solution
The new conveyor system was designed to be simple, flexible,
and productive. It is the product of close teamwork between IMI Cornelius
and Conveyor Solutions Inc., a Schaumburg, IL-based systems integrator and
distributor of Hytrol equipment.
The basic design incorporates two U-shaped conveyor
segments-one for assembly of the refrigeration decks, the other for the lower
housing assembly. The design is compact and efficient, giving employees ample
workspace. It allows for unimpeded communication while affording ready access
to the materials needed for product assembly. The primary conveyor in these
assembly areas is a zero pressure accumulation type (Model 190-SPEZ).
By leveraging the capabilities of EZ Logic, Conveyor
Solutions was able to engineer great flexibility into the system. Both the
refrigeration deck and the lower housing lines incorporate a series of five-foot
work segments. This innovative approach allows management to start and stop
the lines in pre-determined time periods based on customer needs or other
production requirements. The conveyor system in effect becomes an integral
part of the flexible manufacturing process.
When the units are ready to move from one zone
to another, a warning alarm sounds. This tells the workers on the assembly
lines that in 30 seconds the conveyor will start up again. There's also a
set of lights (much like traffic lights, with green indicating go) that visually
guides them. If a worker needs more time to finish a particular task, he
or she can override the system. The conveyor line will not start up again
until the worker has finished the task. This helps ensure that quality
workmanship remains a top priority.
The EZ Logic feature, which controls accumulation
and movement from zone to zone, allows IMI Cornelius to bypass certain work
areas if no assembly work is required. This further enhances flexibility
while increasing productivity. "EZ Logic was really an essential capability,"
says Scott Lee of Conveyor Solutions, who helped design the installation.
"We could not have built this system without it."
The lower housing assembly area also has several
testing stations off the main line. Pop-up transfers move the units off the
main line and onto gravity lines and ball transfer tables, where the testing
is done. Once completed, the units are easily transferred back to the main
line.
The refrigeration decks and the lower housing
units seamlessly merge at a pneumatic ball table just before the final assembly
line. At that point the two units are "married" into a beverage-dispensing
machine. From here, the units are transported on a live roller accumulating
conveyor (190-ABEZ) where the final assembly operations take place.
At the end of the line the completed machines
are positioned onto a belt conveyor, which indexes them through a banding
station. The dispensing machines then move onto gravity conveyors where they
await palletization and transport to the shipping area.
In short, the new conveyor system moves product
through the 45,000 square-foot facility smoothly and efficiently. It's helping
IMI Cornelius keep pace with current worldwide demand for its beverage
dispensers. And more importantly, the system is positioning IMI Cornelius
to support even higher levels of growth in the future.
The Operation at Glendale Heights
The 45,000 square-foot facility has two U-shaped assembly lines-one
for the refrigeration decks, the other for the lower housing. Live roller
accumulating conveyors with EZ Logic are used here. When the units are ready
to move from zone to zone, a warning alarm sounds, telling workers that the
line will re-start in 30 seconds. The refrigeration decks and the lower housing
units merge just before the final assembly line. After they are "married,"
the beverage-dispensing machines move to a live roller conveyor where the
final assembly operations take place. The completed machines then move onto
a belt conveyor, which indexes them though a banding station. They are then
palletized for transport to the shipping area.
A Snapshot of the Facility
Company: IMI Cornelius Inc.
Facility: Focus Factory
Location: Glendale Heights, IL
Size: 45,000 square feet
Director of Operations,
Olympus Facility: Jeff Wright
Product handled: Beverage dispensing equipment
Throughput: Up to 130 beverage dispensers per single shift
Control system: Allen-Bradley PLC
Conveyor supplier: Hytrol Conveyor Inc., Jonesboro, AR
Systems Integrator: Conveyor Solutions Inc., Schaumburg, IL |
Types of conveyors:
- Live roller accumulating
190-ABEZ and 190-SPEZ)
- Horizontal belt (TA)
- Spool transfers
- Chain transfer
- Live roller curves
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