A leading U.S. manufacturer of high-quality acoustic interiors for the automotive industry was experiencing rapid growth and completed a 350,000 square foot addition to their plant in Southern Kentucky to accommodate an increase in production. Although the new addition provided added space, much of it was overtaken for materials used for increased production. Space was still an issue and material flow to manufacturing lines continued to inhibit increased production flow, due to double touch points on materials.
Through extensive time and material flow studies using video of real-time activities, DAK Solutions team designed three separate custom pallet flow systems, each designed to accommodate the different sizes, precisely calibrated to the size and weight of the pallets. Secondly, DAK optimized the flow throughout using a specific degree of slope from load to the removal.
The new systems created over 600 new pallet positions, maximizing the customer’s storage space. Since the systems are both horizontal and vertical, additional flow lanes were double stacked for maximum optimization. And because the pallet flow systems do not require any space for aisles except at the load and discharge ends, floor space was preserved.