Automated handling systems can operate 24 hours a day with minimum staffing and provide a standard of speed, accuracy and quality which would not be possible with manual operations. Paul Farmery, director of Vanriet (UK) expanded on this view. 'Our Netherlands business has supplied vehicle manufacturers such as Volvo with equipment over a number of years but recently we have seen a considerable increase in demand from the automotive sector, from companies such as Pirelli, Dunlop and MG Rover'.
'Vehicle manufacturers do not want to carry stock and production is built around JIT delivery of components to the line.
Each vehicle will have its own individual specification, so every item supplied must match the exact vehicle requirement, in the correct order.
This has led manufacturers to prefer suppliers who have invested in systems which enable them to deliver products on time, in the correct order, often on short notice - and frequently around the clock.
' Andrew Kearton, Operations Manager for Pirelli who recently installed two Vanriet automated conveyor systems, explained how their system works to supply the new Jaguar OS1 type saloon production.
'We deliver a trailer load of tyres and assemblies to Jaguar eight times a day on a 14 hour lead time, a total of 7,500 each week.
Jaguar uses email to confirm what specifications are needed and using the Vanriet conveyor and sortation system we reverse pick the orders, so that when they arrive at the Jaguar plant, they are unloaded in the correct sequence.' Luton-based Magna Seating is gearing up to supply seats for a new range of vehicles produced by IBC, part of Renault GM, early in 2001.
Keith Shaw of Magna Seating's project team explained why increased automation was vital to meet scheduled deliveries to the nearby IBC plant.
'We will be supplying a wide range of seat designs to match the various models and option in the new range, which need to be delivered in sequence, to match vehicle production.
The Vanriet sequencing sorter we have recently installed will play a key role in ensuring our deliveries match IBC's manufacturing schedule, based on two-shift working.
As well as using our labour force more effectively, automated handling systems help us to confirm with health and safety regulations, such as the manual handling directive, by minimising the amount of lifting required.
But when your ability to meet tight schedules depends on a single system, you need to be sure it1s reliable and that the supplier provides effective after-sales support.' For vehicle manufacturers, automated handling systems must be seen as a part of the total manufacturing process, integrated with other automated functions, and operate with compatible software systems.
The design and layout of any handling process must add value - not cost - by ensuring that every move is essential to the manufacturing and assembly functions.
A number of UK based manufacturers have installed AS/RS equipment to handle vehicle bodies, for supplying the paint shop and ultimately the assembly line.
As with other components, bodies need to be fed to the line correctly sequenced, to match the exact vehicle specification.
Vauxhall installed a Morris Material Handling AS/RS system in their Luton plant, to handle bodies at various stages of manufacturing for the Vectra line.
The installation acts as a bank, holding painted bodies ready for the assembly line, others that need repair or additional work, and stocks waiting for components to be delivered.
The 180-body capacity AS/RS system is fully integrated with the main plant conveyor, which takes bodies to and from the assembly line trim shop and the paint shop.
Vauxhall's Steve Circuit explained: ' The system's PLC calls up a vehicle body, reads the identification tag and then feeds it to the main conveyor for routing to the right location.
The system ensures that the assembly line is fed with the right body specification exactly when it1s needed - without the risk of damage which could occur with manual handling.' MG Rover has recently installed an automated component feed system for its relocated 75 model manufacturing plant to supply components sequenced for JIT delivery to the production line.
Stillages of car seats are loaded from fork trucks onto the Vanriet conveyor, which indexes each item to ensure that it matches the specification of each vehicle.
The conveyor keeps pace with the assembly line, to ensure that sets of seats are in the right position for the assembly worker to install into the vehicle.
Could this trend of integrated and complimentary handling systems extend to other sectors?
The automotive industry has developed a supply chain that depends on short lead times and JIT deliveries, to manage costs and at the same time, provide greater customer choice.
Vanriet's Farmery considers where this concept could be most usefully applied.
'Many E-tailers and E-commerce companies may find that a more integrated supply chain may help tackle some of their current problems.
While they may not be able to afford to invest as heavily, adopting the management concept with limited investment in sortation or other systems could help improve their delivery performance.'