| Cooper B-Line Inc. |
SIC: 3444 |
Systems Integrator: FloStor Engineering (Hayward, CA)
Enhanced
Productivity and Ergonomics New
conveyor system integrates standard and customized equipment
to bring multiple benefits to Cooper B-Line Inc. manufacturing
facility.
 Higher
throughput, increased flexibility, less manual handling, reduced
dependence on forklifts. . .these are among the benefits that Cooper
B-Line Inc. has realized from a new conveyor system installed at its Reno
manufacturing facility. Cooper B-Line Inc. is an Illinois-based
manufacturer of electrical, mechanical and telecommunication supports. Its
Reno manufacturing facility specializes in the racks, runway and related
component kits used in the telecommunications industry.
Until the new system was installed just
over a year ago, the Reno facility had no conveyor materials
handling equipment in place. "Basically, we were building
loads on the floor and moving everything around by forklift
truck," recalls Matt Emerson, Cooper B-Line's facilities
engineer. "After we built a pallet load, we would have to
wait around for a forklift and driver to move it before we
could start working on the next order."
The new conveyor system has resulted in an operation
that is not only more productive, but also more ergonomic. It incorporates
both standard conveyor equipment from Hytrol and a unit specially
customized for the Reno facility by FloStor Engineering of Hayward, Calif.
FloStor is an experienced systems integrator and a distributor of Hytrol
conveyor equipment.
Streamlined Order Flow  Material
flow at the Reno manufacturing center is now streamlined and
efficient � and manual handling is kept to a minimum.
Forklifts and transfer carts bring the telecom racks and
runway to the packing stations, which are located adjacent to
the two main conveyor lines. The assemblies are stacked onto
pallets resting on drag chain conveyors at the packing
stations. A typical load would be stacked four feet high and
weigh in excess of 1,000 pounds.
After the pallet is built, chain
transfers move the load onto the main takeaway conveyor line.
There's no more waiting for the forklift to arrive. That
takeaway line is a chain-driven live roller from Hytrol (Model
25-CRR) designed for handling loaded pallets.
 On
the line that handles most of the standard high volume orders,
the pallet loads can take one of two routings. Regular orders
that do not require crating or additional protection pass
through a banding machine and then are transferred to an
order-accumulating conveyor. This is a drag chain unit with an
accumulation module to keep the pallet loads from contacting
one another.
Loads that require crating pass through the banding station
and then move down to the end of the chain-driven line onto a
specialized crating station. Designed for Cooper B-Line Inc.
by FloStor, this unit is actually a combination of transfer
cart, lift table, and conveyor. The crating station moves the
pallet load away from the main line and elevates it, allowing
workers to crate and secure the load safely and efficiently
without bending and handling. Once the crating is finished,
the load is transferred back onto the main takeaway line and
moved either to the order-accumulation station or to the
banding station if additional strapping is required.
The Reno facility also includes a second line, which is
dedicated to OEM customers. This line is similar to the main
line except that it does not have the specialized crating
station.
The Reno facility also handles the kits of cable runway and
other components that typically accompany the rack shipments.
The conveyor system handles the flow of these kits as well.
Higher Throughput and
More
 The
installation at Reno is a good example of how standard
conveyors can be effectively integrated with customized units
to deliver multiple benefits. "We're now seeing
throughput levels that are 30 to 35 percent greater than what
we had before the system was installed," says Facilities
Engineer Emerson. He adds that the Reno facility now averages
about 150 racks per line in an eight-hour shift.
The new conveyor system also has enabled Cooper B-Line Inc.
to more effectively secure the pallet loads. Operators can
control the positioning of the pallets as they move through
the banding machines. This results in more precise banding and
enhanced load security.
Finally, workers can do their jobs more efficiently and
with a lot less strain. The heavy-duty chain transfers move
the loads effortlessly onto the takeaway lines. And the
adjustable crating stations allow workers to crate and secure
orders with minimum bending and maximum access to the load.
In short, the new conveyor system can be considered a
win/win/win for Cooper B-Line Inc., its workers, and its
customers.
Cooper B-Line's
Manufacturing Facility
 Pallet
loads are built at the packing stations, located adjacent to
the two main takeaway lines. When the loads are completed,
heavy-duty transfers move them from the drag chain conveyor
and onto the takeaway line, a chain-driven live roller
conveyor. On the north line, which is dedicated to OEM
customers, the loads move through the banding station and are
then transferred onto an order-accumulating conveyor. On the
south line, the loads go through the banding station and then
move either to the order-accumulating conveyor or to the
specialized crating station. After crating, the orders are
moved backed to the order-accumulating unit.
Snapshot of the Operation
Company: Cooper B-Line Inc.
Facility: Manufacturing Plant
Location: Reno, NV
Size: 175,000 square feet
Employees: 302 (three shifts)
Key Personnel: Facilities Engineer Matt Emerson,
Senior VP Operations Bill Corray, Project Engineer Gary
Griesbaum, Plant Manager Jeff DeMatei
Product handled: Telecom racks, runway and kits
Throughput: 150 racks per line (avg.) per shift
Types of conveyors: Chain-driven live roller (25-CRR), drag chain
(DC-60), heavy duty chain transfers, crating station
Conveyor supplier: Hytrol Conveyor Co. Inc., Jonesboro, AR
Systems Integrator: FloStor Engineering Inc., Hayward,
CA.
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