Fleximate® Transport Systems: Integrated Stations with Carts and Tracks
This product is our Hybrid Ergonomic Workstation and Conveyor. Stations are joined together by track tubes and the WIP flows through the stations on Transport Carts rolling on the track tubes. We have two standard track/cart widths 12” and 18”. Our standard cart weight capacities are either 75 or 150# depending on your requirements. An auxiliary worksurface is available with our Flowmate® option. The system can also be customized as required. The following videos depict standard and customized stations, carts and cells.
This 100-foot-long cell is an example of a straight ESD cell with single unit flow and on line test for a high volume electro-mechanical product.
This cell features single piece production with improved ergonomics, supermarket parts presentation, tool handling, on line test and many other enhancements.
This cell produces a heavy mechanical product. Our fixturing provided manipulation and rotation in two planes which combined with a optimized track height provided efficient worker ergonomics and simple product transfer.
Two long cells for a 250# product. The unique cart design enabled operators to online inspect for QC. Production flow was a combination of free and powered conveyance.
Two custom Fleximate® cells featuring unique overhead return of empty pallets due to unique fixturing. Cart tops featured rotation for this high-volume automotive application.
This application includes a progressive flow through a low temperature oven in a clean room. Also featured is a post cure powered section for cool down, Custom workstations were integrated into the line to minimize handling of the heavy product and fixture.
This complex mechanical assembly required some fresh thinking for multi access assembly. Custom work surfaces assisted in worker ergonomics and assembly productivity.
This cell featured a re-manufactured product which required that all reused components remain together. We provided a means of keeping the family of parts together with the product housing.
Online supermarket parts presentation supporting a high volume, high mix production schedule.
In this application, fixturing and parts presentation was created to produce completely different products. Sub assembly stations produced at point of use with quick change over capability to support mixed model flow. An overhead lift with a lifting yoke made packaging safe, single operator operation.
Electromechanical assembly cell with fixturing challenges. Also included was a product tilt assist that transitioned the process from an unsafe, two operator lift to a semi-automated, single operator, ergonomic operation.
This cell successfully transitioned a high mix, low volume production from batch to single piece, progressive production. The design wish list included the ability to handle high torque assembly, dual test bays without production constrictions and an anti-tip safety feature.
An in-depth assembly examination yielded some beneficial fixture considerations. An end of cell, lifting arrangement made packaging a safe, single operator process
This mature product was transitioning to a single piece flow with standard work procedures. We incorporated ergonomic fixtures and a high-pressure test process in line and yielded high productivity.
Multiple work height stations, high performance ESD control and integration of a UV cure tunnel were just a few of the requirements for this electronic product’s production.
This cell features universal fixturing for multiple models, product lift assist by a single operator and the ability to be staffed by 1 to three operators. A shuttle system provided a simple method for empty fixture and cart return from the end of the cell to the head.
ESD Assembly Cell 2020 d1
This project involved the mixed model assembly of a heavy product. Objectives included: error proofing, improved production flow, enhanced assembly ergonomics and maximizing space utilization.
A constriction free, multi-unit, one piece flow, test cell used for high mix production flow.
See a “U” configured assembly cell with ESD protection that allows the team to work “one, one down” depending on product mix and production volume. Right sizing delivers maximum space utilization in tight quarters. Powered empty cart return with elevators at each end of the line eliminated operators having to deal with empty carts.
A right sized cell for a 100-pound product that single piece flows to point of use.
A slow and steady production ramp up forced this company to take a high-level review on how to meet the escalating demand. The product weights ranged from 85 to 160 pounds and jockeying it through production was consuming labor and driving productivity down. Worksmarts’ Fleximate® Transport System to the rescue with its combination of ergonomic, modular workstations with a product conveyance.
This cell had a few challenges: fast paced; high mix electro-mechanical production; a lengthy in-line test cycle; flex staffing of 1 or 2 operators; and very limited floor space. The current methods had the operators wrestling and carrying product through the various processes. With these hurdles and much input from the client, Worksmart Systens designed, a compact 11’ x 15’ ,“U” configured Cell, utilizing our Fleximate® Transport System.
Having too much space can be as problematic as having too little. The directive was to make the cell for assembling a 250-pound robot as direct, compact and frictionless as possible. This 6 position, “L” configured cell would have to tuck into a tight space. The integration of a Turnstyle with our Fleximate® Ergonomic Transport System, was key to meeting this requirement.
