Creating Success For 35 years
Challenge:
Challenge:
Challenge:
Challenge:
Challenge:
Challenge:
Challenge:
Challenge:
Years of Outdated Equipment & Processes
The Challenge
The customer was challenged with employing a state-of-the-art facility from outdated equipment and processes. They had been operating from the same facility for over 20 years and were desperately ready for an upgrade in all arenas.
Their dated equipment featured roller conveyors that aren’t in much use anymore. They wished to bring their facility into the 21st century with exceptional technology and modernized equipment.
The Solution
With our team’s guidance and expertise, the company was able to formulate a transition from their outdated facility to a world-class manufacturing standard. Tekno worked with the customer’s team to design and install the new processes with Tekno equipment.
We provided conveyor equipment as well as sound barriers for testing equipment. Additionally, we installed pallets and partnered with a trusted source for tooling needs.
For the customer’s Manufacturing Execution System, Tekno aided the process so that work instructions could display on screen as pallets are coming down the line, providing an additional layer of efficiency not available before.
Tekno’s equipment is standardized, therefore providing the ability to apply it in many ways to meet many needs. In this instance we were able to provide for all the needs of this customer’s new facility with very minimal customization requirements. The mechanical and electrical engineering on this project was well-within Tekno’s wheelhouse and we were confident and well-versed in the implementation of this kind of process.
The Result
Providing a successful product and process is instrumental in providing a first-rate facility. Tekno’s experience and ability to create a standardized system that still met the customer’s specific needs allowed for the smooth launch of a modern and efficient factory.
The launch of the new facility was extremely successful, resulting in minimal down time. The customer is now up and running a more efficient process on updated equipment that will last a long time.
If the customer ever wishes to take advantage of Tekno’s standard equipment and expertise in the future, we will be there to provide them with the tools needed to help their facility thrive.
Loading of Products was too slow & Labor Intensive
The Challenge
This client is a leader in providing kitting, warehousing, and logistics to the world’s largest manufacturers. They bring value to their customers by providing efficient and reliable delivery of product from the component assembly plants to the general assembly plants. The loading and unloading of their products was slow, time consuming, labor intensive, and product damage was possible.
The Solution
Tekno manufacturing engineers analyzed the problem and designed the perfect solution. Tekno supplied six automated shipping trailers that automatically load products at the component plant and the automated shipping trailers unload products at the general assembly plant.
The Result
The Tekno engineered solution and automated shipping trailers provided the customer with a solution that loads/unloads products in record time, reduces labor to almost zero, and eliminates the product damage.
Manual Storage & Retrieval System was Slow & Labor Intensive
The Challenge
This long-time customer needed to make enhancements to their shipping system. With the additional products being added to the shipping requirements they had to have a more dynamic system that would be able to pick products based on their customer’s requirement.
The Solution
Tekno engineers developed a solution and implementation plan. Tekno provided three Storage and Retrieval Crane Systems, which moves completed products and stores the products in a static racking system. The software system tracks the inventory in the racking system and allows quick search and query of the stored products. The system compares the existing inventory with the customers’ requirements and pulls the products accordingly. The conveyor system that accompanied the cranes stores products in a “ready to ship” sequence, so the products are quickly loaded into trailers as the customer pulls them to ship.
The Result
The Tekno solution provided the customer with a comprehensive system that greatly improved the customer’s total inventory, picking and shipping operations. The customer now has equipment and software that efficiently manages their inventory. The automated system rapidly stores and retrieves inventory when needed, which boosts productivity. The system is almost labor free saving time and resources.
Upgrade Needed To Process New and Existing Products
The Challenge
The automotive customer needed to upgrade their current front row assembly line to handle a new product. They also need enhancements made to their existing assembly lines. The work had to be completed quickly to meet the deadline for their new launch.
The Solution
Tekno’s manufacturing engineers reviewed the project and developed a plan to add new material handling equipment that modified the customer’s existing assembly line and process to seamlessly incorporate the new the new products. In addition, upgraded automation equipment was engineered into their existing assembly lines for their existing products.
The Result
Ahead of their deadline, the Tekno solution successfully and seamlessly implemented the customer’s new products into their existing line. Also, Tekno provided enhancements to the customer’s existing assembly lines that greatly improved their productivity, reduced downtime, and created huge savings through improved process efficiencies.
Shipping Solution Needed For Inventory Shared By Two Companies
The Challenge
This unique project included two Tekno customers under one roof. The two companies, who share a building, share equipment used to ship their completed products to their respective customers. Although the Tekno customers saved money by sharing the facility, it also created logistical and management difficulties, which was time and labor intensive.
The Solution
Tekno engineered an incredibly effective solution. The Tekno system delivers the product from the assembly line to a storage and retrieval system. The storage system keeps the completed product in individual storage locations until the product is required to ship. Once a shipping list is received, the list is fed into the Tekno system, and the products are transported through a series of conveyors to a two-level truck “simulator”. The Simulator stores the products as a completed truck load. When a truck docks at the facility, it connects with the Tekno conveyor system and automatically loads the trailer.
The Result
The Tekno Solution provides the customer with a comprehensive system that effectively and efficiently moves their products through their facility in a highly organized and managed process. This entire process runs without operators and runs automatically 24/7. Our client received a greatly enhanced process that saves time and resources. The system ensures that the clients’ customers receive the right products… and quicker than ever before. It is a huge improvement to Tekno’s customers’ bottomline.
Assembly Line Needed Upgrades and Large Expansion
The Challenge
Tekno has serviced this automotive company for over 25 years, and each year model changes are very intense. Production lines always require modifications to handle the new vehicles and components. The client needed a complete turn-key assembly line for their 2nd row seat assembly system. The client also needed additions to their existing front row seat system to allow for additional rework and processing. Completion was required during a shutdown period of less than one week.
The Solution
The Tekno Team worked closely with the client’s engineers and management team. Tekno rapidly analyzed the challenge, created a plan, built the required equipment and performed the installation in record time. During the project, Tekno introduced advanced automation solutions that added enhancements to the client’s line and assembly process. This provided improved productivity and measurable efficiencies.
The Result
The client’s assembly lines and processes were created and installed on time and on budget. Tekno’s engineers provided improvements to the client’s original plan to provide additional productivity and savings in time and resources. The customer was extremely satisfied.
Additional Buffers Needed For Offload Robots
The Challenge
This customer had a logistics problem on their assembly line. The problem area of the assembly caused the entire line to stop, the team was idled, productivity was reduced and production costs increased. The problem was handled manually and took lots of time.
The Solution
Tekno engineers reviewed the problem and designed the perfect solution. In a very tight space, Tekno created an additional buffer between their offload robot and the end of the assembly line that provided the necessary storage capacity. Tekno implemented a new heavy duty table top conveyor to storage lanes where completed products are held until the robot was ready to unload. Additionally Tekno’s engineers provided backup solutions which ensured the system could continue to function if one piece of equipment was inoperable until it could be re-engaged.
The Result
The client’s problem was solved quickly and on-budget. In addition, Tekno provided an advanced system and improved process for handling the products on their assembly line, which provided even greater productivity and savings. The client also received valuable “peace of mind” to run their production without fear of shut downs.
New Production Facility Required New Manufacturing System
The Challenge
This second tier automotive customer built a new production facility onto an existing plant to produce a new line of products. The customer was on a tight budget and deadline.
The Solution
Tekno’s engineering team thoroughly reviewed the facility and products and designed a manufacturing plan. The solution perfectly fit the location, the client’s budget and timeframe. Tekno produced four complete assembly lines that were custom fit to their needs. These assembly lines produced front seats, second row seats and third row seats, as well as a separate seat back assembly line.
The Result
From inventory entering the building to finished products being shipped out of the building, Tekno provided the perfect end-to-end solution. The project was the perfect for Tekno’s Total Manufacturing Solutions. Tekno’s conveyors serve as the foundation of the project, and Tekno’s Automation equipment provides the highest possible levels of productivity and efficiency. Also, Tekno worked closely with the client’s team to ensure their maintenance staff and engineers were knowledgeable and comfortable with the equipment.