BMW gets more mileage from flexible flow track
Auto maker opts for a flexible, conveyor-like, gravity flow track system-driving increased ergonomics for workers, maximizing space.
By Staff -- Modern Materials Handling, 11/1/1998
When BMW Manufacturing Corp. of Spartanburg County, S.C., became the sole producer of the Z3 roadster, the industrial shelving in the current facility couldn't handle the increased flow of parts. Management needed a tough and flexible gravity flow track, one that would perform under heavy use.BMW prides itself on true craftsmanship, and the Z3 roadster is assembled in a less than automated environment. The production line utilizes manual labor instead of machines, making the flow of parts an immense priority.
The auto maker wanted to maximize every square foot of its plant. Management knew it would eventually have to store more parts in a small area. Suppliers were asked to design a system that could deliver small packages to the workers, who, in turn, could get the parts directly onto the vehicles.
After completing an evaluation, point by point, a system was chosen due to its flexibility.
"In my opinion, it's incredible," says Chip McMillan, manager of manufacturing and operations control at BMW. "For the auto industry, with the amount of parts increases that we have, this flow track allows us to increase the pick locations at a station by expanding the beam width and putting in more track."
Another factor influencing the selection was that the lanes can be used for various size packages. In the auto industry it is not uncommon to receive the same part at the production line in various box sizes. This is where BMW needed flexibility.
"You can take the track and move it from one rack to another," says McMillan, "You don't use any nuts and bolts to install the flow track onto the framing system."
The system fits into new or existing pallet racks, spanning and supported by the pallet rack beams. This utilizes strength of the rack structure and makes maximum use of rack capacity since no shelves or intermediate supports are needed.
One of the biggest problems for BMW workers was the inability to pick at the pick face. They couldn't get their hands down into the boxes. Expanding the beams too far would only reduce the number of pick faces, clearly unacceptable. The flow track allows workers to get into the picking zone and pick the part from the box.
The new rack system has a stair-step design. It offers the ability to have the different pick faces offset. Workers can directly reach into a box without having to reach beneath the rack.
"The ergonomics of this system, having the flow from the knee to the shoulder," says McMillan, "makes it easier for us to design it to the work station.''
Additionally, the system was easy for BMW to install. To learn how to set up and manipulate the rack to specifications, BMW workers themselves installed the product.
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