AGV-powered custom carousel sequences parts in a smaller footprint

Modular Automotive Systems, a division of Hollingsworth Logistics Group, provides front and rear fascia assemblies in sequence for an automotive OEM on a just-in-time basis. After installing a series of customized carousels, the company was able to increase productivity with less floor space for less money than traditional alternatives.

The company’s assembly process began with fascia outer shells being placed on carts equipped with protective cradles. Carts were manually moved through production cells where associates employ handheld scanners. The final step was a quality control station before parts were loaded in proper sequence on mobile racks and delivered to OEM assembly plants. The process was labor intensive and also required a considerable amount of production floor space.

“We were familiar with carousel assembly systems, but we also knew this method could be cost prohibitive,” says Christian Cantrell, program manager and process engineer for MAS. “Before installing the new system, our initial target was to handle 50 fascias in 47 minutes and the first carousel was able to do it in 36 minutes. The best part is that each carousel cost about 15% of the total of just one traditional carousel unit.”

While working with a supplier (Creform, creform.com) to create a continuously moving assembly line, several ideas were considered. Proposals included a paper clip-shaped route and moving cart concept before the team settled on a circular carousel system. The system was installed and operational within eight weeks.

The new system features eight stations and provides each associate with a pie-shaped work zone that uses about 50% less floor space. Each cart has a custom-configured rack and rides on a circular rail that is bolted in position on the floor. The carousel is powered by a low-speed, bolt-on style automatic guided vehicle (AGV) unit attached under the lead cart. It travels at 0.05 mph, (1.5meters/minute) and has a load capacity of 1,496 pounds (680 kg).

“It is virtually impossible for a fascia to get out of sequence since they are only handled when being placed on or removed from the cart,” says Cantrell.