Material Handling Solutions for the Automotive Industry

 

The automotive industry is in a constant state of change. Always adding new models or modifying existing ones, adjusting for new contracts or shifts in production requirements, automotive suppliers need a conveyor system that can keep up.

IntelliTrak’s friction drive system (no chains) and modular support structure (bolted, not welded) is easily modified, making it the ideal solution for automotive applications:

  • Easily add workstations to increase production and cycle time.
  • Forward/Reverse capabilities improve the efficiency of the assembly process and save space.
  • Zone control, enabled by VFDs and gear box ratio changes, provide varying speeds and speed changes between workstations and high transfer speeds around corners.
  • No chain means a clean work environment and a clean finished product.

Take a look at how IntelliTrak Conveyor Systems have changed how our customers do business:

 

Flexibility to increase production and improve cycle time.

Opportunity:
Automotive manufacturer needed an overhead conveyor system for their door assembly line.

Solution:
The inherent flexibility of the IntelliTrak 500 Series Overhead Conveyor is what sold this automotive manufacturer. IntelliTrak’s friction drive system (no chains) and modular support structure (bolted, not welded) can be easily reconfigured at any point in time. In fact, the system has already been modified several times to add workstations to increase production and cycle time. In addition, the forward/reverse capabilities improved the efficiency of the assembly process and saved valuable floor space.


Repeat customer, Tier 1 Automotive supplier, adds new vehicle line, expands system and saves money.


Opportunity:
In 2006, IntelliTrak installed a system in the customer’s new building.
When they were awarded a new contract in 2015, they had a choice: purchase a new conveyor system or modify the existing one.

Solution:
The inherent flexibility of the IntelliTrak 500 Series Overhead Conveyor made the decision simple: MODIFY it!
Instead of having to build an entirely new system (as they would have had to do with a traditional power and free chain system), IntelliTrak was able to remove part of the old system, add new conveyor onto the old system, reuse some of the existing system, and save the customer thousands of dollars in both equipment and downtime.

Scope of project:

The customer’s assembly requirements were complex—add 12 new stations with rotating motorized carriers equipped with RFID and powered conductor rail, taking into account the need for:

  • 52 second TAKT time
  • 42 minute same day delivery
  • 90 second electrical test
  • Accumulation for 2 HLA stations
  • Indexing
  • Broadcast pull parts from accumulation in order

Complex assembly made easy, increasing TAKT time and competitive advantage.


Opportunity:
A supplier of automotive interiors needed an overhead conveyor system for their new facility.

Solution:
IntelliTrak designed, manufactured and installed a 500 Series Overhead Conveyor System that included 41 assembly work stations with 4 test zones and level 2 software controls to manage work stations. The new overhead conveyor not only freed up floor space, but gave them a real competitive advantage by allowing them to meet an extremely fast TAKT time of 75 jobs per hour.


A more efficient system with a smaller footprint.


Opportunity:
Having already installed an IntelliTrak Conveyor System in another location, when it came time to purchase a conveyor system for a new facility with limited floor space, the decision was easy for this supplier of automotive interiors.

Solution:
IntelliTrak designed, manufactured and installed a custom inverted (floor-mounted) conveyor with an over/under design to make the most of limited floor space. The system consisted of 5 assembly stations at floor level, with cantilever lifts on each end for elevated return of empty carriers. A more efficient system, with a smaller footprint.


IntelliTrak 150 Series—the ideal solution for accumulation, staging and product transfer.


Opportunity:
A supplier of automotive interiors needed a conveyor system that would store 12 hours of production, accumulate efficiently, handle left-handed and right-handed IP assemblies, with a limited footprint (keeping walkways between lanes), while meeting a 45 second TAKT time.

Solution:
The IntelliTrak 150 Series Overhead Conveyor, with a max load of 150 lbs. and 100+ fpm, was tailor-made for this application. IntelliTrak designed, manufactured and installed approximately 3,000 ft. of conveyor, a mezzanine, 2 levels of storage, 693 carriers, with a line speed of 45 ft./min., and incline/decline speed at 60 ft./min.


A more efficient way to transfer engines


Opportunity:
Automotive manufacturer needed an efficient way to move engines from assembly to shipping and return carriers to assembly without excess conveyor taking up floor space. Not only did it have to fit within the limited footprint, it also had to interface with customer’s existing equipment and meet required TAKT time.

Solution:
IntelliTrak designed, manufactured and installed a custom 1500 Series Overhead Conveyor saving the customer valuable floor space and meeting required TAKT time.