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Oki Data Americas, Inc.
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SIC: 3577
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Hytrol Distributor: Stokes Material Handling
Systems (Doylestown, PA)
Integrated System Pays Multiple Dividends
Oki Data streamlines
order flow, boosts efficiency with integrated
series of conveyors.
As a leader in the manufacture and
distribution of PC printers, facsimiles, and accessories, Oki Data is
continually striving to upgrade all facets of its operation. A good
example of this can be seen at the company's administrative and operations
complex in Mt. Laurel, N.J., which also serves as headquarters for Oki
Data Americas.
 The upgraded facility today features a
streamlined order-flow system that efficiently moves product from the
production area through to the shipping dock. But prior to the new
installation becoming operational in the fall of 1998, that desired level
of efficiency was not always being reached. The old system was a largely
manual operation with a limited amount of conveyorization in place.
Operators had to do an excessive amount of walking and handling to build
the pallets by hand. On occasion, there were major backups and bottlenecks
that needed to be addressed.
Oki Data knew that to support a growing
business it needed to upgrade its order-flow capabilities. Specifically,
it needed higher efficiency, a more ergonomically friendly operation, and
the capacity to accommodate both current demand and future growth. The
company met those objectives with an integrated conveyor system featuring
Hytrol equipment. Stokes Material Handling Systems of Doylestown, Pa., did
the systems integration, including the computer controls. Stokes is a
distributor of Hytrol conveyor equipment.
The design process and subsequent
installation went extremely well, reports Dan Rinck, Oki Data's manager of
manufacturing engineering. A big reason for that, he says, was an
inclusive approach that sought input from all of the key stakeholders.
"People from our production, engineering, and warehousing areas all
worked closely with Stokes in the design effort," Rinck says.
"It was truly a team effort."
The operators who actually build the pallet
loads participated in the process as well. Their involvement had two
important benefits. "They gave us a lot of good input," says
Rinck. "Plus their early involvement made them more comfortable with
the system and gained their acceptance very quickly." In a short
period of time, the engineering manager notes, the operators were
performing at a high level of productivity.
Integrated and Efficient
The
installation seamlessly integrates multiple conveyor types in a
streamlined order flow. Cases of computer printers and fax machines move
from the production area to the distribution center on live roller
conveyors. They are inducted onto a re-circulation loop comprised of
horizontal accumulating and belt conveyor segments. The accumulating
conveyor (Model 190-ABEZ) includes Hytrol's exclusive EZ Logic feature. EZ
Logic effectively controls the release of product from zone to zone,
preventing back-ups and related problems.
 "EZ Logic has done what we hoped it would
do," comments Rinck. "After making a couple of adjustments early
on, we have been able to virtually eliminate any jamming in this
area."
Belt-driven
(SC) sorters divert the cases from the re-circulation loop down one of
four lanes where the pallet loads are built. (Cases not read properly or
being held for line changes remain on the loop.) The cases move off the
re-circulation loop and down a belt conveyor that leads to a short gravity
segment. Operators
take the cases off the gravity conveyor and proceed to build pallet loads
on an adjacent drag chain conveyor. This model (DC-60) is specifically
designed to handle pallets safely and efficiently. Equipped with the
special accumulation module, the conveyor allows the pallets to accumulate
with "zero-back pressure." This greatly reduces the possibility
of collision that could result in product damage.  The
completed pallet loads move off the drag chain conveyor onto a
chain-driven roller conveyor (Model 25-CRR). This unit transfers the
pallets to the main line�a chain-driven accumulation conveyor�that
leads to the stretch wrapping stations. There are two automated stretch
wrappers: a primary and an auxiliary wrapper.
Once
the pallets are stretched wrapped, they are released onto gravity
conveyors. Forklifts then transport the completed orders to the
shipment-staging area or to storage. Product shipped from this facility
serves customers in the eastern half of the United States. Oki Data also
operates a distribution center in Milpitas, California.
Ready for the Future
 For
an installation with as many different conveyor types, the operation is
actually quite simple and straightforward. It's also ergonomically sound,
minimizing the amount of lifting and movement required of the operators.
The Mt. Laurel facility is forward looking,
too. While today it is efficiently handling an order volume of
approximately 2,000 cases a day, the design approach provides for easy
expansion should future business needs dictate. "We could easily and
cost-effectively expand the system by extending the re-circulation loop
and adding two more lanes for pallet building," says Rinck. By doing
this, the system could handle an estimated 25 percent increase in order
volume.
Bottom line: the new installation is
helping Oki Data position itself for both today and tomorrow.
An Overview of the Operation
Multiple
conveyor types are seamlessly integrated to move product though the
300,000 square-foot facility. Live roller units transport boxes of
computer printers and fax machines from production to a recirculation loop
in the distribution area. This conveyor segment incorporates EZ Logic,
which controls accumulation of cases from zone to zone. Sorters divert the
cases down one of four lanes for pallet building. Pallets are built on
drag chain conveyors and then moved to a main line of chain-driven
accumulating. After passing through an automated stretch wrapper, the
completed orders are taken by forklift to shipment
staging or storage. The facility handles about 2,000 cases a day.
Snapshot of the Facility
Company:
Oki Data Americas,
Inc.
Facility: Operations Center
Location: Mount Laurel, NJ
Size: 300,000 square feet
Employees: 300 (approx.)
Manager of Manufacturing Engineering: Dan Rinck
Product handled: Computer printers, fax machines, accessories
Throughput: 2,000 cases/day
Types of conveyors: Horizontal accumulating (EZ Logic), belt,
sortation, chain-driven roller, chain-driven accumulating, drag chain,
gravity
Control System: Allen-Bradley plc with touch screen and pc-based
sort control
Conveyor Supplier: Hytrol Conveyor Inc., Jonesboro, AR
Systems Integrator: Stokes Material Handling Systems (Doylestown,
PA)
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