The Challenge
As the principal contract integrator at a leading UK automotive manufacturing facility, Daifuku Europe required Automatica's expertise to implement a just-in-time (JIT) tailgate delivery solution. This solution needed to manage the continuous flow of automotive parts and integrate seamlessly with the existing automated storage and retrieval systems (ASRS).
The Automatica Solution
Leveraging our extensive experience in designing and manufacturing customised automation systems, Automatica collaborated with Daifuku to develop the mechanical components of their innovative JIT tailgate delivery solution.
The system featured a unique docking mechanism, enabling trailers to dock seamlessly at the client's facility. This facilitated the efficient unloading of fully loaded platens and the reloading of empty platens, optimising material handling processes. The incorporation of a 'false lorry' design allowed for simultaneous transfers, significantly reducing trailer turnaround times.
Additionally, the system integrated an ASRS crane provided by Daifuku, offering flexible storage and retrieval capabilities adaptable to changes in the production schedule. This ensured continuous alignment with manufacturing demands and enhanced overall operational efficiency.
The conveyor system comprised 24V powered roller conveyor modules, chosen for their energy efficiency—achieving an 80% energy saving compared to traditional 415V systems—and exceptionally quiet operation.
To accommodate dual production lines within the facility, two identical systems were implemented. Each included 24V driven roller conveyor modules, turntables, drop sections, shuttle cars, and lift-up gate sections, all designed for seamless integration and reliable performance.
Throughout the project, Automatica collaborated closely with Daifuku, combining our automation and automotive industry expertise to identify opportunities for increased speed, noise reduction, and innovative solutions.
The Result
The tailored JIT tailgate delivery system immediately enhanced the productivity and efficiency of the car manufacturing process, providing a competitive edge for the client. Platens moved in a continuous flow, fully supported by the ASRS, ensuring timely and accurate delivery aligned with production demands.
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