CAUTION THIS VEHICLE MAKES TIGHT TURNS
Detroit Diesel: Last October Detroit Diesel, a division of Daimler, unveiled the DD15—a new heavy-duty diesel engine ready to set new efficiency standards for the industry. The engine manufacturer spent five years and $1.5 billion to develop the new 6-cylinder engine, which displaces 14.8 liters and is available in all Daimler Trucks North America products. Designed as an international engine, the DD15 will eventually be manufactured by Daimler Trucks in Germany, Japan and the United States. To manufacture the new engine, Detroit Diesel invested $275 million to refurbish and retool its 3-million-square-foot manufacturing plant in Redford, Mich. That project included new materials handling and storage processes to support the lean manufacturing line. “If you look back to 2003 when we began designing the new engine, we were a traditional manufacturing facility with no well-defined storage locations,” says Chris Russell, material flow engineering supervisor. “To produce the DD15, we had to create a central warehouse area, with narrow-aisle high bay storage to free up space for the new assembly line.” The central warehouse area takes up just 30,000 square feet, considerably less than the 80,000 square feet of space that was previously used throughout the plant. Some of that space is available for other manufacturers that lease space from Detroit Diesel. “At any given time, as much as a third of the plant is utilized by mall tenants who lease from us,” says Russell. “One of our goals is to not only free up more space for our products, but also to open up space for manufacturing tenants.” In addition, Detroit Diesel implemented a kanban system to pull material to the line on a just-in-time basis rather than store parts and components at the line. One of the keys to making these new processes work was a series of specially designed carts (Topper Industrial, 262-886-6931, www.topperindustrial.com) that are used with tuggers and automatic guided vehicles (AGVs) to deliver parts and components to the line just in time, and in some cases, in sequence (see p. 24 for a description of the carts). In place of a traditional assembly line, the AGVs route the engines from one workstation to the next during the manufacturing process. While Detroit Diesel is still ramping up production of the DD15, the manufacturer is already seeing productivity rise. “We have improved our on-time delivery of parts from the storage area to the line,” says Russell. “And we're seeing improvements in quality.” The new engine line created an opportunity to implement lean manufacturing processes at Detroit Diesel. To support manufacturing, the materials flow team set out a number of materials handling goals. They included: * Shortening the distance between the receiving docks, the storage area for parts and components, and the point of use. To meet this goal, Detroit Diesel created a centrally located 30,000 square foot warehouse area with very narrow aisle, high bay storage. Prior to that, most inventory was stored on the floor and positioned throughout the warehouse. Once the location for the storage area was established, Detroit Diesel relocated the receiving area adjacent to the warehouse. That sped up the receiving and putaway time. “The receiving area was quite a distance from the central warehouse,” says Russell. “We did an analysis that proved we could justify the cost of putting in a new receiving dock with productivity improvements.” Enable 100% inventory accuracy. The manufacturer employs a warehouse management system (WMS) that supports dynamic storage to make most efficient use of the storage locations and to track the location of inventory in real time. The last, and possibly most important, goal was to establish robust and efficient replenishment systems along the whole process chain. The most important change was philosophical: The facility transitioned from a push system, where lift truck drivers managed the delivery of parts to the line, to a pull system, where parts were delivered as requested by workstation operators. “Previously, our lift truck drivers had a milk run; they went to a storage area, picked up parts and delivered the material to the line based on their schedule,” Russell explains. “We wanted to decouple those processes.” That decoupling led to the implementation of a kanban system to pull bulk materials through the system on a just-in-time basis. That, in turn, drove important materials handling changes. In the new system, palletized materials are delivered to each work area on a cart. Each cart has a cardholder on the side with information about where the cart is stored and where it's delivered. The cart also has a simple flag that resembles the flag on an old-fashioned mailbox. When the operator on the line uses the last part on a cart, the flag is raised. That signals to the tugger driver that more material is needed. The driver returns the empty cart to a staging area; unloads any dunnage; and drops the card off in a mailbox. Later, that card will be retrieved and scanned by a warehouse operator, triggering replenishment. Transitioning to a kanban system not only reduces the amount of inventory stored at the line, it also reduced the number of times production was slowed because a work cell was out of stock. “We recognized that in a lean environment, we could no longer have employees managing their own stock, or deciding when to deliver parts to the line,” says Russell. “We couldn't risk shutting down the line.” One year after Detroit Diesel unveiled the new engine design, the line is producing about 50 engines a day, with capacity to produce as many as 300 engines a day. As production ramps up, Russell's team intends to implement an electronic kanban system that will automatically send a signal when a part is ready for replenishment. While still not at full production, Russell says the new system is already delivering improvements. “During implementation, we began tracking things like the hours per engine, which is a measure of how efficiently we are manufacturing, and first-time through, which is whether all of the parts were on hand to produce a finished engine the first-time through, even if we didn't shut down the line,” he says. “We are seeing improvements on all of those measures.” To move an engine the size and weight of the DD15 and its components in a fork truck-free environment required a series of specially designed carts. They included: Engine block cart. Designed to carry four engine blocks weighing 2,000-pounds each with a power transfer system that comes from the tugger's electrical system. Crankshaft cart. Includes gravity conveyors and positions for eight crankshafts. The cart interfaces with gravity conveyors at “the supermarket,” where parts are sequenced and staged for delivery, and the assembly line. The 100% mechanical system includes automatic transfer and safety features, including the ability to disable the tugger during transfers. Cylinder liner cart. Has positions for two 48-inch x 45-inch pallets. The cart includes a power transfer, which is also powered by the electrical system of the tugger. Mother cart for kit carts. Travels with an automatic guided vehicle (AGV) on the assembly line with components built just for that engine. At the end of the line, the kit cart is pushed on to any mother cart for return to the “supermarket.” Dolly cart. Delivers full and empty dollies around the plant. It was designed with a self-elevating platform that keeps the parts at an ergonomic height for loading and unloading. Rotation cart. Allows the operator on the line to rotate the top of the cart to keep parts close, reducing the need to reach. The cart features a retractable storage shelf to temporarily store packaging dunnage for the operator. Small parts delivery cart. Features adjustable shelves and is usually pulled in a train. This gives the operator many options to pick and pull small parts.
Recently Topper Industrial was awarded the IPS Supplier Award by DaimlerChrysler. The IPS Supplier Award is based on surveys completed on average, 3 times per month by the plant and corporate material handling engineers, and project managers. The surveys consist of 20 questions covering these criteria; quality, cost, technology, and project management. Each area is given a rating of 1-6 with 1 being the best. Overall, Topper Industrial achieved a rating of 1.4., making Topper Industrial one of DaimlerChrysler’s most valued suppliers with the best ranking in the awards history. The in demand QuadSteer cart is Topper’s most recent innovation. QuadSteer carts are used primarily in tugging situations where the cart remains attached to the tugger to deliver commodities in a specific route. With all four wheels turning, the radius of the rear wheels follow the front wheels, thereby creating better cornering. This also allows more carts to be tugged together because there is no drifting to the inside. Regardless of the number hitched together, they would all follow the same track around the corner. The QuadSteer cart can be fitted with many options including racks, rollers, caster upgrades and a variety of hitch set-ups. One of the most versatile tilt carts on the market is our new 75º Ergo-Tilt-Cart developed to make it easier for individuals to reach commodities at their work station or on the assembly line, especially long vertical pieces. Using the patent pending automatic speed control valve and closed-loop dampening cylinder gives excellent control over the load energy regardless of the center of gravity. The 75º Ergo-Tilt-Cart comes in many standard sizes or can be customized to meet specific applications.
DAIMLER CHRYSLER AWARDS Topper Industrial, Inc. of Sturtevant, Wisconsin was presented the 2006 IPS Supplier Award, DaimlerChrysler's highest honor given to suppliers on April 19, 2007 at the Walter P. Chrysler Museum in Auburn Hills, Michigan. Jim Sorensen, director of Global Procurement, presented Ed Brown, President of Topper Industrial, Inc with the award. “We are extremely proud to accept this award from DaimlerChrysler. I accept this award on behalf of all our employees, for without them it would not be possible. We have worked closely with Corporate Engineers, Plant Engineers and Plant Personnel to build innovative equipment that’s safe, dependable and ergonomically friendly. We look forward to challenges ahead and are committed to make each new system the best possible.” (Ed Brown) The IPS (International Procurement Service) Supplier Award was awarded to only three DaimlerChrysler suppliers; Topper Industrial (Material Handling Equipment) Walbridge Aldinger (Construction) and Infosys (IT Solutions). The three recipients where chosen from over 2,000 North American suppliers with annual purchases totaling well over 2 billion dollars. Topper Industrial is the only material handling product manufacturer to ever earn the IPS Supplier award. The IPS Supplier Award is based on surveys completed on average, 3 times per month by the plant and corporate material handling engineers, and project managers. The surveys consist of 20 questions covering these criteria; quality, cost, technology, and project management. Each area is given a rating of 1-6 with 1 being the best. Overall, Topper Industrial achieved a rating of 1.4., making Topper Industrial one of DaimlerChrysler’s most valued suppliers with the best ranking in the awards history. "The success of Topper Industrial and the products we design and manufacture for customers like DaimlerChrysler, is a direct result of offering world class products, service and commitment. We are fraction of the size of the other two companies that also earned this award, yet we stand equal in the level of quality and innovation. We have a very dedicated and talented group of people who realize the importance of this recognition" says Ryan Brown, Vice President.
OPTIMIZE TIME WITH THE NEW TRANS4MER CART Sturtevant, WI –September 23, 2008 - Topper Industrial, a leading material handling equipment manufacturing introduces the TRANS4MER cart. The TRANS4MER cart is a (4) four-wheel steering cart that transforms into a (2) two-wheel steering, hand-operated pushcart. The TRANS4MER cart was designed to optimize efficiency. Having a cart that is equally as maneuverable as it is while being pulled by a tugger or pushed by an operator saves time and effort. Topper is leading the fork truck free movement and the innovative design of the TRANS4MER makes it easier for a company to go from using fork trucks to using tuggers and a train of carts. The TRANS4MER cart functions when the tow bar is tipped down, the cart transforms from a pushcart into a (4) four-wheel steering cart. To return the (4) four-wheel steering cart to push cart mode, the operator simply lifts the tow bar upwards. Topper Industrial is a leading material handling equipment manufacturer with an emphasis on fork truck free environments. Topper Industrial products are widely used within the automotive industry and are changing the way material is moved within an assembly plant. Topper Industrial designs custom solutions for a variety of manufacturing customers.
SLIDING TOWBAR / QUICK COUPLER Sturtevant, WI -June 24, 2008 - Topper Industrial continues to lead the way in designing material handling products that focus on function. The Topper quick coupler and sliding tow bar makes attaching and detaching carts an effortless process. There is no bending over or lifting to hook the carts up. Just grap the soft red grip at waist level on the sliding tow bar and guide the pintle ring right into the rear coupler. The pintle ring is spring-loaded to hold it in the exact location for the receiver. Connection is made automatically with the spring-loaded lug in the coupler, which is easily released for uncoupling by a simple foot depression. When coupling carts or adding Topper carts to a train of carts the operator simply pushes the cart up against another and then pulls it away. Upon pulling the cart away from the other the carts it will be connect by a heavyduty tow bar for smooth towing and cornering. The greatest feature of this tow package is the automatic release of the floor lock as the tow bar is extended so that the floor lock is never down when being towed where it can be "ripped off". This feature allows loading these carts in a semi-trailer with the floor lock set and the tow bar retracted for space and safety. To unload the semi trailer, the carts can be pulled out as a train with tow bars extended and brakes released with forward pulling. In this way you can get a 70-foot train out of a 53-foot trailer. Topper Industrial is a leading material handling equipment manufacturer with an emphasis on safe, fork truck free environments. Topper Industrial products are widely used within the automotive industry and are changing the way material is moved within an assembly plant. Topper Industrial designs custom material handling solutions for a variety of World Class manufacturers.
SELF LEVELING DOLLY CART Sturtevant, WI -June 24, 2008 - Topper Industrial continues to lead the way in ergonomically designed material handling products. The self-leveling dolly cart is a prime example of the innovation at Topper Industrial. The self-leveling dolly cart is spring loaded keeping a rack or bin of parts always at the perfect height for the operator to comfortably reach for its contents. When additional racks are added to the dolly, the springs compress to accommodate multiple racks. As a rack is removed the next rack rises as the spring expands. Carts can be designed for any weight and size. Topper Industrial offers a wide variety corral carts. Corral carts secures multiple dolly carts for easy transport by tugger. The corral cart / dolly configuration is commonly referred to as a mother / daughter cart. Mother daughter carts make it easy for full carts to be delivered to the assembly line and empty ones returned. As more manufacturers move to a lean, fork truck free environment, Topper’s innovative products are there to make a process safer and more efficient. Topper Industrial is a leading material handling equipment manufacturer with an emphasis on safe, fork truck free environments. Topper Industrial products are widely used within the automotive industry and are changing the way material is moved within an assembly plant. Topper Industrial designs custom material handling solutions for a variety of World Class manufacturers.
SAFE, EASY AND EFFICIENT Sturtevant, WI -May 10, 2006 - Innovation strikes again at Topper Industrial with the introduction of a self-adjusting dampening valve available on all Topper Industrial tilt carts. It no longer matters if the load being tilted is a few hundred pounds or a couple thousand pounds, the load will tilt at the same speed regardless of the center of gravity. Topper Industrial is the only material handling equipment manufacturer to offer this patent pending feature on their carts. Users can tilt a nearly full container as effortlessly as they can an empty container. The self adjusting valve eliminates the need to manually adjust based on load weight and all risk of accident because of an improper adjustment. The self adjusting valve lets manufacturers use the versatile Topper tilt carts throughout the plant without having to mannually adjust the valve for a specific application. The self adjusting valve is available on many size tilt and rotate carts. Topper Industrial is a leading material handling equipment manufacturer with an emphasis on fork truck free environments. Topper Industrial products are widely used within the automotive industry and are changing the way material is moved within an assembly plant. Topper Industrial designs custom solutions for a variety manufacturing customers.
Sturtevant, WI -May 10, 2006 - One of the most versatile tilt carts on the market is Topper Industrial's powered tilt cart. The powered tilt cart can operate on as little as 60 psi and can tilt up to 2,500. Not only is tilting easy the powered tilt cart can tilt side-to-side, front-to-back and uneven loads. As with all Topper Industrial's products, safety is the highest priority that is way the powered tilt cart uses Topper's automatic valve to control the tilt, speed of tilt and angle. An operator is always in control of the cart's load. Every Topper cart comes is standard sizes with a variety of options or can be customized for a specific application. The power tilt cart is on wheels making is easy to be moved anywhere an air hose will reach. Topper Industrial is a leading material handling equipment manufacturer with an emphasis on fork truck free environments. Topper Industrial products are widely used within the automotive industry and are changing the way material is moved within an assembly plant. Topper Industrial designs custom solutions for a variety manufacturing customers.
WIDER DEGREE OF ERGONOMICS Sturtevant, WI -May 10, 2006 - Topper Industrial is leading the way in material handling safety and ergonomics. Our new 75º tilt cart was developed to make it easier for individuals to reach commodities at their work station or on the assembly line especially long vertical pieces. Using the patent pending automatic speed control valve and closed-loop dampening cylinder to give excellent control of the load energy regardless of the center of gravity. The 75º tilt cart comes in many standard sizes or can be customized to meet specific applications. Topper Industrial is a leading material handling equipment manufacturer with an emphasis on safe, fork truck free environments. Topper Industrial products are widely used within the automotive industry and are changing the way material is moved within an assembly plant. Topper Industrial designs custom material handling solutions for a variety of world class manufacturers, from one cart to an entire production facility.
THE ALL WHEEL DRIVE CART Sturtevant, WI -May 10, 2006 - Topper Industrial is leading the way in material handling in a fork truck free environment. Introducing the all new knuckle-steer cart. This new all wheel cart is the most stable lightweight cart on the market. The all wheel cart allows for maximum manueverability and stability when delivering material by tugger to an assembly line, warehousing or loading dock areas with in a plant. Trains of 8-10 all wheel carts are possible with absolutely no swaying or serpentining while pulling because the wheels are always in line at the four corners. Topper Industrial is a leading material handling equipment manufacturer with an emphasis on safe, fork truck free environments. Topper Industrial products are widely used within the automotive industry and are changing the way material is moved within an assembly plant. Topper Industrial designs custom material handling solutions for a variety of world class manufacturers, from one cart to an entire production facility.
THE TOPPER ROTATE TABLE GETS LIGHTER Sturtevant, WI -May 10, 2006 - Topper Industrial makes improvements to their popular lightweight rotate table. Keeping with their efforts to bring safe ergonomic products to the marketplace Topper has been able to reduce the over all weight of their rotate table by 60 lbs. No longer is it necessary to move a heavy metal slab around, the design improvements include a light weight frame designed for heavy loads. Not only does this cart stay within the standard ergonomic window but is also easier to rotate and move around. All Topper carts, lifts and containers come in standard sizes or can be customized to meet a specific application. Topper Industrial is a leading material handling equipment manufacturer with an emphasis on safe, fork truck free environments. Topper Industrial products are widely used within the automotive industry and are changing the way material is moved within an assembly plant. Topper Industrial designs custom material handling solutions for a variety of world class manufacturers, from one cart to an entire production facility.
SAFELY AND EASILY TRANSFER HEAVY LOADS Sturtevant, WI -May 10, 2006 - The Topper Industrial transfer conveyor cart allows for easy movement of up to 4,000 lbs loads with a tugger. What makes the transfer conveyor cart easy to use is the foot controls and the double locking mechanisms ensure the load is moved safely. As with all Topper Industrial products innovative features can be added such as an electric eye to make sure the cart is always in position prior to transfer. The transfer conveyor cart comes in standard sizes or can be customized to meet specific applications. Topper Industrial is a leading material handling equipment manufacturer with an emphasis on safe, fork truck free environments. Topper Industrial products are widely used within the automotive industry and are changing the way material is moved within an assembly plant. Topper Industrial designs custom material handling solutions for a variety of world class manufacturers, from one cart to an entire production facility.
COMPLETELY UNLOAD AN ENTIRE RACK Sturtevant, WI -May 10, 2006 - In keeping with developing safe, ergonomic, innovative material handling products Topper Industrial introduces the slide shelf rack. The slide shelf rack allows an operator to unload an entire rack from one side eliminating the need to rotate a shelf rack. The Topper Industrial slide shelf rack in constructed with non-rusting roller mechanism which improves the life of the equipment. To allow more room for commodities, light-weight, durable, thin trays are used. The slide shelf rack come in many standard sizes but id often designed to meet specific requirements depending on the commodity and assembly application. Topper Industrial is a leading material handling equipment manufacturer with an emphasis on safe, fork truck free environments. Topper Industrial products are widely used within the automotive industry and are changing the way material is moved within an assembly plant. Topper Industrial designs custom material handling solutions for a variety of world class manufacturers, from one cart to an entire production facility.
THE SURFACE AS TOUGH AS THE CART Sturtevant, WI -July 11, 2006 - Topper Industrial continues to be a leading material handling solution company by being the first to include a Line-X surface on its bulk dollies. Line-X, the industry pioneer and worldwide leader in sprayed-on polyurethane linings, continues to redefine "toughness". Line-X thick, durable linings provide superior protection for products placed on Topper carts as well as keeping the cart itself protected from scratching and denting. "Adding Line-X to the surface of our carts prevents the sliding of containers and dampens the noise during transport." Says Ed Brown, President of Topper Industrial. He adds, "As far as we can tell Topper is the only cart manufacturer using Line-X." Topper Industrial is a leading material handling equipment manufacturer with an emphasis on fork truck free environments. Topper Industrial products are widely used within the automotive industry and are changing the way material is moved within an assembly plant. Topper Industrial designs custom solutions for a variety of manufacturing customers. - END |
