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Custom Rack/Dunage: Machined Automotive Component

Custom Rack/Dunage: Machined Automotive Component

In one of its assembly operations that utilized heavy, vacuum formed trays for parts handling during FY 2011 and 2012, an automotive OEM had eight ESI, one OSHA and two LTI cases that were determined to have a cost impact of $118,902. ThermoFlex eliminated these issues by  replacing the trays using an existing rack then supplying injection molded TPU urethane dunnage. In addition this eliminated five steps in the dunnage loading process, completely eliminated part contamination issues and the need for shrink wrapping. The bottom line cost savings of all these issues was $305,991 per year.

PROBLEM

An Automotive OEM was facing a number of ergonomic and quality issues that were resolved after implementing a Kaizen program and partnering with ThermoFlex. Team members were experiencing wrist injuries from using a pinch grip to lift parts from trays, shoulder injuries from lifting the vacuum formed trays when empty and back injuries from bending to set/pick dunnage. Parts also had occurrences of packaging contamination due to the dunnage. The photos below demonstrate the problem.

Custom Rack/Dunage: Machined Automotive Component

SOLUTION

ThermoFlex engineered a program that required a replacement rack and TPU injection molded urethane dunnage but eliminated the instances of injuries, part contamination and reduced logistics costs while providing a payback in 1.2 years. It is a simplistic solution because the parts are easily gripped and slid out of the dunnage with no twisting motions while retrieving them or lifting the empty heavy dunnage trays.

Custom Rack/Dunage: Machined Automotive Component

There are several economic implications that factor into an annual cost savings of $305,991 per year and a 1.2-year new program cost payback.

Custom Rack/Dunage: Machined Automotive Component


Download the case study PDF here.