MANUFACTURING Ascend Communications Controller Manufacturing, Alameda, Calif.
Each packed carton receives a bar coded label that identifies the customer purchase order and Ascend model number.
By Staff -- Modern Materials Handling, 2/1/1999
Ascend Communications builds hundreds of network controllers to its customer's specifications each day. No two controllers are alike, and Ascend meets this complexity problem with a simple, flexible manufacturing scheme.A U-shaped conveyor line feeds work-in-process (WIP) to multiple workstations. Workers direct pallet loads of WIP from station to station, which paces production, allowing the company to meet customer requirements.
The result is two conveyor-based manufacturing lines, using minimum floor space, that can build lot sizes of one.
On its busiest days, Ascend pumps through a combined total of 600 network controllers on the two lines.
The manufacturing done on the two lines is final assembly and configuration of telephone network controllers. Nearly finished controllers arrive at the 150,000 sq ft facility from contract manufacturers.
Ascend completes assembly only when orders are in hand. During the night, the order management system downloads orders to the manufacturing control system.
Unfinished controllers are picked from pallet rack, accessories from flow rack, and packaging materials from floor storage. Controllers are transferred to a staging area behind the first workstation on the two lines.
While one manufacturing line is dedicated to a single unit, the other builds 10 different units. A manipulator moves the single unit onto a slave pallet at the first workstation. Units on the other line can be manually placed on pallets.
Twelve workstations on each line, six on each side, perform hardware configuration, software download, testing, system configuration, testing, and packaging. At the first workstation, a sales order printout detailing required assembly steps is attached to the unit on a slave pallet.
Ascend uses a coding system to route slave pallets to the workstations. Workers move a reflective slider on the side of the pallet until it covers the number of the next sequential workstation. Pallets recirculate on the conveyor until it passes through each designated workstation.
A boxed, finished unit is carried by the assembly conveyor to the vertical lift for delivery to the 10 ft high elevated conveyor and transported to shipping.
Shipping labels are printed and applied to cartons. A final bar code is generated that includes the serial and shipment numbers, and a listing of the carton contents. Delivery of the carton to the shipping dock is by a final conveyor segment.
As Ascend's line of controllers expands, there are plans to add a third manufacturing line similar to the other two.
Product manufactured: Telephone network controllers
System integrator: FloStor Engineering 510-887-7179
Conveyors: Hytrol 870-935-3700
Vertical lifts: Integrated Systems 800-705-6401
Pallet control system: Joslyn Clark Controls 803-286-8491
Hoists: Knight Industries 810-377-4950
Manipulators: Lifting Assist Technologies 800-456-1140
Control software: Serra Systems 707-433-5104
Flow rack: Inca Metal Products 972-436-5581
Bar code label printers: Zebra Technologies 847-634-6700
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