| System Profile: Masterlock Distribution Center |
SIC: 3400 |
Masterlock Doubles Throughput with Hytrol
Customer:
Masterlock Distribution Center
(Distributor of Padlocks)
System Integrator:
Babush Material Handling Systems
Milwaukee, Wisconsin |
A view of the two main transport lines which move
the product from the picking area to the sorting conveyor.
The case bar-code scanner is incorporated into the
Hytrol conveyor system.
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Masterlock’s main objective when they opened a new facility in
Louisville, Kentucky, was to increase capacity. Not only was this goal
achieved but a number of other benefits were also realized.
Throughput was increased from 15 cases per labor hour to over 32. Cycle
time was decreased from four days to 24 hours. Conveyor capacity jumped
from 400 cases per hour to 1500 cases an hour.
How the System works:
The system transports cases of locks which are manually picked and placed
on five infeed conveyor lines. One line is used for cut-case products.
The other four lines are designated for all other products.
The first infeed line is equipped with a photo-eye which the pickers
and packers can use to start and stop the line. The pickers/packers here
may repack if needed, then send the order to the main transport line.
The other four lines feed into two main transport lines where they are
scanned and weighed. These two main transport lines move the product around
to the sortation conveyor (Hytrol Model ProSort 131). This sortation conveyor
has twenty-one, 30 degree, diverts. There are fourteen, 20 ft. long and
seven, 40 ft. long decline gravity conveyors to move the completed order
to shipping.
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