SAY GOODBYE TO WELDED CARTS AND HELLO TO THE MODULAR CART SYSTEM FOR FLEXIBLE MATERIAL HANDLING

Transcription

1 SAY GOODBYE TO WELDED CARTS AND HELLO TO THE MODULAR CART SYSTEM FOR FLEXIBLE MATERIAL HANDLING

2 Serve all steps in your supply chain! PRE ASSEMBLY WAREHOUSE PREPARATION FlexQube solutions can be used in different areas throughout the facility. From inbound material handling to final assembly. A common case where FlexQube is used is internal transportation of material between preparation/picking areas to assembly and manufacturing stations. TRANSPORT INTERNAL TRANSPORTS FINAL ASSEMBLY Various carts and racks combined in a tugger train makes it possible to create an efficient process. At the same time fork lift traffic can be reduced and create a more safe environment.

3 FlexQube transforms your needs into a solution CHALLENGES AND NEEDS BUILDING BLOCKS DESIGN TOOLS INTRALOGISTICS SOLUTION DESIGN4ALL TM YOU CREATE THE CART!? BUI LDI NG BL OC DESIGNONDEMAND TM KS FLEXQUBE CREATE THE CART!

4 Volume/number of variants Reducing the product dedicated cost The manufacturing industry have gone through a change where the variants of products increases and the volume of each variant decreases. MORE VARIANTS The increase of variants is mainly due to more customer configuration and the shorter life cycle is caused both by the faster development of technology and the need to stay relevant in a competitive market. In a ever changing environment the need for flexibility and modularity is crucial. By using the FlexQube concept you can reduce the product dedicated cost for each variant due to the possibility to re-use and re-design material handling equipment. $ $ $ LOWER VOLUME / VARIANT SHORTER LIFE CYCLES PROFIT FROM A PRODUCT MUST BE EARNED DURING A SHORTER PERIOD OF TIME

5 The FlexQube concept help address challenges INTRALOGISTIC NEEDS ENABLERS FLEXIBLE LAYOUT AND EQUIPMENT CART BASED TRANSPORTS RECONFIGURABLE CARTS MOVABLE LINE SIDE CARTS PARTS AND KIT PREPARATION CUSTOMIZED CARTS ROBUST CARTS ERGONOMIC DESIGNS SAFE & FREQUENT TRANSPORTS AND FAST CART DESIGNS DESIGN4ALL TM DESIGNONDEMAND TM FORK FREE PRODUCTION & TUGGER TRAINS EFFICIENT DESIGN PROCESS MOVER INTEGRATION

6 Go Forklift free with FlexQube FORKLIFTS ARE HEAVY DANGEROUS FOR PEOPLE AND EQUIPMENT 100 FATAL ACCIDENTS A YEAR, ONLY IN THE U.S ACCIDENTS FORKLIFTS ARE MADE FOR LIFTING, NOT FOR MOVING

7 FLEXQUBE HAS INCREASED OUR PRODUCTIVITY BY 25% IN MATERIAL HANDLING Ted Tackeberry Carcoustics

8 Delivering to the most demanding customers, worldwide FlexQube works with large companies globally. Most of the customers are based in Europe, USA, Mexico and Canada. By working with demanding customers from various industries, FlexQube have a huge experience when it comes to creating good solutions for all situation. With manufacturing in both North America and Europe, FlexQube can offer a global concept that works across continents.

9 Official references I have received very good feedback from the operators. The assembly of the parts, the strength, the capacity. It is all great! You have a hit here guys! Steve Dillion, Logistics Project Manager at Siemens Energy Inc. Very good from an ergonomic standpoint. Stable and easy to maneuver and to push manually. The solutions are very stable despite their clean design. We are very satisfied! Operators and Production Engineer at Johnson Controls I am extremely satisfied with the carts. I feel proud when I see them at the production lines or when the carts are transported by the tugger train. They have a very solid design, very robust. Maritza Segovia, Logistics Engineer at Eberspächer Exhaust Technology

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11 Standard building blocks The FlexQube concept consits of standard building blocks that are used in various combinations to build different solutions for material handling. The FlexBeam (1) and the FlexTube (2) are used to build the framework in the solutions. The FlexQube (3) and the FlexPlate (4) are used for connections and joints. Other joints and attachments are used to create specific functions for the solutions. It depends on what type of material that will be transported and how it will be presented

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13 The FlexQube Interface There is a standard in the FlexQube system that evolves around the number 7. The FlexBeams and FlexTubes comes in lengths in increments of 7 cm as you can see to in the bottom right picture. This means there is no cutting of parts to fit specific lengths but instead the existing building blocks are used. The FlexQube interface is shown in the picture to the left below. It appears everywhere on the building blocks as you put the system together. This makes it possible to keep building and placing new parts on the interface you create when building.

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15 Building blocks enable many different couplings X-Joints T-Joints L-Joints

16 DESIGN4ALL YOU CREATE THE CART DESIGN 1. CREATING FLEXQUBE CARTS IS EASY AND FUN 2. NOBODY KNOW THE NEEDS BETTER THAN YOU 3. DESIGN4ALL ENABLES EVERYONE TO DESIGN THEIR OWN SOLUTION 4. CAD LIBRARY IS AVAILABLE FOR DOWNLOAD FOR ALL MAJOR CAD SOFTWARES

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18 DESIGNONDEMAND FAST AND EASY DESIGN OPTION 1. PREPARATION 2. WEB MEETING 3. DESIGN 4. DELIVERY You and your team prepare some basic information about what you are looking for Your team will interact with a professional FlexQube designer and your requirements will be transformed into a cart design FlexQube finalize the cart design and prepare information such as pictures, drawings, 3d models and quote The carts can be delivered just as building blocks together with assembly instruction, or completely assembled

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20 Summary 12 reasons to invest in the FlexQube concept PLATFORM INDEPENDENT DESIGN4ALL DESIGNONDEMAND GLOBAL DISTRIBUTION WIDE CUSTOMER BASE INDUSTRY KNOWLEDGE REPLACE WELDED CARTS FLEXIBLE DELIVERY OPTIONS STANDARDISED EASY TO REPAIR 3D DOCUMENTATION INTEGRATION WITH OTHER CART CONCEPTS

21 The possibilities are endless! Find inspiration online

22 USER CASE Eberspächer (Exhaust Part Manufacturing) CHALLENGE Reduce forklift traffic in the factory Many parts with different size, weight and geometry Narrow transport aisles ACHIEVEMENT 60% reduced travel distance for material in the production Improved loading and picking ergonomics Reduced number of forklifts SOLUTION Customized kit carts built with FlexQube standard components Integration with Liftrunner tugger train from STILL Common and flexible platform used as base for all kit carts

23 DETAILED STORY Eberspächer wanted to go fork-free in their production and improve the material flow. FlexQube was contacted and the first carts were implemented in Since then, the customer has continuously modified and upgraded the carts. Both to suit new demands but also to take care of feedback from the operators to improve the carts even more. The FlexQube concept makes that possible without discarding parts, making it a sustainable solution for the industry. By replacing forklifts with a mother/daughter tugger train to feed material to the welding lines it was possible to transport more material in every delivery. Instead of feeding one pallet at a time, four carts with material are transported to the line simultaneously. The carts were designed in close cooperation with the operators that use the carts daily, and for them it was a big change. The carts have been a huge improvement when it comes to ergonomics. The material are easily rolled on and off the cart to the assembly station. Always in a good height and close to the body Thanks to the implementation of FlexQube carts, the distance that parts are travelling was reduced with as much as 60% percent. Also the engineers are happy with the carts. I am extremely satisfied with the carts. I feel proud when I see them at the production lines or when the carts are transported by the tugger train. They have a very solid design, very robust The customer has more than 300 carts in 15 different versions

24 USER CASE AGCO (Tractor Fabrication) CHALLENGE Existing carts not flexible enough and hard to move manually Too many forklifts in production Heavy parts and many different variants of parts ACHIEVEMENT I think it is just great! It rolls easy no matter how much parts you load on it Very good picking ergonomics Reduced forklift traffic Heavy duty shelf carts for welded parts and customized carts Carts moved with E-frame Liftrunner tugger train from KION SOLUTION Adjustable shelves that can be adapted for different parts

25 DETAILED STORY AGCO has a lot of variation in their production process and are in need of a flexible system that can be adapted to variation in the design of the components. AGCO uses the FlexQube concept to assemble customized carts that can hold the fabricated parts between work stations and machine centers. Each cart is either transported by the Liftrunner E-frame tugger system or by a standard tongue and hitch solution. We have been using the FlexQube system since 2013 and are very happy with the functionality and performance. -Plant logistics manager

26 USER CASE Heavy truck cab assembly CHALLENGE Too many forklifts in production High ergonomic requirements Narrow forklift aisles ACHIEVEMENT Reduced number of forklifts More safe and quiet working environment Several pallets can be transported at the same time SOLUTION Pallet cart 1200 X 800 mm with tow bar Supply with train including 4 carts Caster setup for optimal tracking

27 DETAILED STORY Reduced forklift traffic was the main target for the customer in this case. Transportation of 1200x800 mm pallets and 800x600 mm should from now on be moved on carts. As the frequency of deliveries to the assembly line was high, the ergonomic conditions for the operator was very important. Based on FlexQube standard building blocks two different platforms was designed, one for each size of pallet. The commonality of building blocks between the platforms was as high as 90% which simplifies maintenance and storage of spare parts. To handle the narrow forklift aisles with it was important to achieve narrow turning radius and exceptional tracking. This was achieved with a caster configuration including two fixed casters in the center of the cart, and one swivel caster in each short end of the cart. For excellent ergonomics the carts were equipped with an ergonomic tow bar that is controlled from the handle. This invention from FlexQube reduced many non ergonomic movements for the operators when connecting carts into a train. Train with 4 carts runs from the warehouse to the kit lines located close to the assembly line. The carts can be removed in any sequence from the train thanks to the ergonomic tow bar. A handlebar with bent top makes sure the cart are easy to push into the correct position on the line. In total 800 carts was delivered.

28 USER CASE Brose (Automotive Parts) CHALLENGE 100% forklift free production area Different sized containers High ergonomic and safety requirements ACHIEVEMENT From 24x15 inch to 50x50 inch carts with FlexQube system All cart types fit Liftrunner E-frame Ergonomic features like fixed brake pedal and removable handle bars SOLUTION From 24x15 inch to 50x50 inch carts with FlexQube system All cart types fit Liftrunner E-frame Ergonomic features like fixed brake pedal and removable handle bars

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30 LOW RIDER FLAT DECK CART 46 X 49 INCH Q Low rider 46 x 49 inch cart for containers/pallets with the deck just 7 inch off the ground! Handlebar and spring loaded drawbar Six heavy duty Polyurethane casters ensure great tracking and easy maneuvering Customer reference is Dräxlmaier in SC who has about 150 units of this cart Cart can be equipped with foot release tow bar or other types of casters

31 FLAT DECK TUGGER CART 50 X 50 INCH Q This is by far our most popular cart on the North American market. Manufactured in Swainsboro, GA we ship this cart out on a weekly basis. With a solid flat steel deck this cart is ready to take some beating! 2000 lbs. capacity and six heavy duty casters for great tracking behind the tugger Removable handlebar, floor brake and foot release tow bar (no need to bend down to release the hitch) Can also be delivered without steel deck and with drop pin hitch system instead

32 LOW RIDER TUGGER CART 50 X 50 INCH Q inch wide and 50 inch long low rider tugger cart without flat deck for containers This industrial tugger train cart is equipped with tow bar, either heavy duty tow bar or the foot release tow bar developed by FlexQube. The caster configurations enable great tracking properties for the train set. It is also equipped with handlebar for easy handling.

33 FLAT SHELF CART 63 x 33 INCH Q Shelf Cart in size 63 x 33 inch Shelf height can easily be adjusted up and down The design can be adjusted with more/less shelves Cart is equipped with foot release tow bar but can be delivered with drop pin hitch system as well With six heavy duty casters this cart track very well behind a tugger and several can be connected in a train Possible to add Floor lock rake / Handlebars or other features using our standardized interface

34 4 IN 1 MOTHER DAUGHTER CART SYSTEM Q in 1 Mother Daughter Cart Solution where small carts can be removed from the large cart and placed at work-stations. The mother carts are tuggable and several connected form a tugger train The carts can be used to kit-part from a warehouse and then transported to the assembly line and placed there, bringing a empty on back to the warehouse for replenishment. You can customize the number of and the position of the shelves

35 TOOL CART Q Tool cart perfect at the assembly line Very common to equip with peg board for tools Angled shelves Lower shelf with rollers for handling boxes AGCO in Jackson, Minnesota have about 75 of these carts in use

36 BUILDING BLOCKS - FLEXBEAM LENGTH STANDARD FLAT END 350 mm 13.8 Q Q mm 16.5 Q Q Standard 490 mm 19.3 Q Q mm 22.0 Q Q mm 24.8 Q Q mm 27.5 Q Q mm 30.3 Q Q mm 33.0 Q Q mm 35.8 Q Q mm 38.5 Q Q mm 41.3 Q Q mm 44.1 Q Q Flat End 1190 mm 46.8 Q Q mm 49.6 Q Q mm 52.4 Q Q mm 55.1 Q Q mm 57.9 Q Q mm 60.6 Q Q mm 63.4 Q Q

37 BUILDING BLOCKS - FLEXTUBE LENGTH OUTER INNER 70 mm 2.7 Q mm 5.5 Q mm 8.2 Q mm 11.0 Q mm 13.8 Q mm 16.5 Q mm 19.3 Q mm 22.0 Q mm 24.8 Q mm 27.5 Q Q mm 30.3 Q mm 33.0 Q mm 35.8 Q mm 38.5 Q mm 41.3 Q mm 44.1 Q mm 46.8 Q

38 JOINTS AND STANDARD BUILDING BLOCKS Beam to Beam Corner Plate Q Pallet Guide Corner Plate Q Handlebar Attachment Q Heavy Duty Joint Q Wheel Attachment for Casters with Diameter of 125 or less Q Handlebar Attachment + Floor Brake Attachment Plate Q Stiffener Outside Q Wheel Attachment Box (All Casters) Q Handlebar Tube Q L-Bracket Joint Q Wheel Attachment for Casters with Diameter of 200 mm or more Q M6 Screw (for all Standard Interface) Q M10 x 90 Hex Head Q T-Joint Q FlexQube Q Collet for FlexBeam Q M10 x 90 Flat Head Q Cross Joint Q FlexPlate Q FlexPlate M10 Q FlexPlate Half Q Locking Nut M10 Q M10 x 25 Hex Head Q

39 TOW BARS WIRE-RELEASE TOW BAR Unique tow bar that is controlled using the handle bar (1) Wire makes tow pin move accordingly (2) Ergonomic solution that eliminates bending for operators FOOT-RELEASE TOW BAR Tow bar that is controlled by foot (3) Spring connection moves tow pin Ergonomic solution that eliminates bending for operators DROP-PIN TOW BAR Tow bar handled by hand Drop pin is placed in hole on tow bar to lock with next cart (4) Requires bending from operator

40 Contact us CEO Anders Fogelberg +1 (678) Sales North America Andy Legut