In today's automotive industry, precision and efficiency go hand in hand with economy and ecology. Such was the challenge faced by an automotive engine manufacturer that was looking for a solution to the problem of internal transportation of delicate components - engine heads and bodies. The manufacturing plant, which specializes in producing high-quality drive units, needed a comprehensive logistics solution that would meet the demands of a modern production line.
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Challenge
The customer struggled with an inefficient conveyor system using trays made of a combination of wood and composite. The main problem was not only the unrecyclability of the materials, but above all the need for special protection of the ground surfaces of the heads and engine bodies. Even the slightest scratching of these components could lead to leaks and, consequently, to serious engine malfunctions.
Transportation between the machining and cutting department and the assembly department required special precision and protection. Previous solutions did not guarantee adequate protection of delicate surfaces, which translated into an increased risk of damage and potential production losses. In addition, the production scale of 15,000 units required a solution that was both effective and economical.
Naturally, we took up the challenge, providing an innovative and fully customized solution tailored to the customer's needs.
Solution
Geo Globe Poland's team undertook a comprehensive analysis of the problem, starting with a detailed audit of the plant's logistics processes. After detailed research and consultations with the customer, it was decided to use ABS material. The choice was not accidental - this material guaranteed the precision of the tray sockets and the maintenance of shape stability, which was crucial for the safety of transported components. Geo Globe Poland's engineers conducted a series of material tests, which showed that the initially considered HDPE, despite its lower price, was ruled out because it was too flexible, which could jeopardize the stability of the transported components. ABS, on the other hand, provided the ideal combination of rigidity, resistance to mechanical damage and precision manufacturing.
It is worth noting that the implementation process itself included several prototyping stages, during which different variants of the solution were tested. Special attention was paid to optimizing the amount of material used, keeping in mind both the economic and environmental aspects of the project. Each prototype was thoroughly tested in a production environment, which allowed for a number of improvements and optimizations.
The effect? See for yourself!
The end result - what did the customer gain?
The results of the project exceeded the client's wildest expectations. During the prototyping process, it was possible to achieve a difference in the use of material reaching As much as 66% compared to the solutions originally considered!
With the production of 15,000 trays, this translated into significant savings in the project budget, estimated at hundreds of thousands of zlotys per year. What's more, designed transport trays not only met all quality and safety requirements, but also fit into the idea of a closed-loop economy. After the end of their original use, the trays were given a "second life," which further increased the environmental value of the entire solution.
ABS material used in the project is fully recycled, which significantly reduces the environmental footprint of the production process. The implemented solution also helped optimize the entire logistics process at the plant. Precisely designed slots in the transport trays streamlined the process of loading and unloading components, which translated into shorter logistics operations.
At Geo Globe Poland, today we create solutions that streamline processes and tomorrow build a sustainable and efficient future for your business.
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