The die casting manufacturing industry deals with producing high-quality metal components through the die casting process. The industry’s success relies on efficient storage and retrieval of fixtures, molds, and other essential materials. To enhance productivity and streamline operations, the company decided to implement an automated storage and retrieval system. The scope of this case study is to detail the successful deployment of the “LeanStore” automated vertical storage solution, equipped with Tray Extraction and a customized system-mounted hoist with a 1-ton capacity.
Challenges: The manual storage and retrieval process in the die casting industry posed several challenges, including:
- Space Constraints: Limited floor space for storage resulted in congestion and inefficiencies.
- Manual Handling: The workforce was exposed to safety risks due to the manual lifting of heavy fixtures.
- Inventory Management: Difficulty in locating and tracking specific fixtures led to time wastage and errors.
Solution Deployed: Automated Vertical Storage Solution – LeanStore: After a thorough evaluation of various automated storage solutions, the die casting manufacturing industry opted for LeanStore, a highly advanced and customizable automated vertical storage system. The key highlights of the solution provided are as follows:
- Highly Customized Solution: The LeanStore system was tailored to the specific needs of the die casting industry. It offers a remarkable 1-ton carrying capacity per tray, accommodating even the heaviest fixtures with ease.
- Tray Extraction Facility for Easy Retrieval: The automated system features a tray extraction mechanism, allowing workers to effortlessly access the required fixtures without manually handling heavy loads. The trays are ergonomically designed to prevent any damage to the stored materials.
- Inventory Management System: LeanStore is integrated with a sophisticated inventory management system. This system provides a user-friendly interface for the seamless tracking and management of stored materials. Each fixture is assigned a unique identifier, making it easy to search, store, and retrieve the required material efficiently.
- System-Mounted Hoist for Safe Handling: To ensure maximum safety during the handling of heavy materials, the LeanStore system comes equipped with a custom-built, system-mounted hoist. The 1-ton capacity hoist enables workers to pick up and place heavy materials with almost zero risk of accidents or injuries.
Implementation and Results: The implementation of the LeanStore automated storage and retrieval system resulted in significant improvements for the die casting manufacturing industry:
- Enhanced Productivity: With quick and efficient access to fixtures and molds, the production process experienced a notable boost in productivity.
- Space Optimization: The vertical storage solution optimized floor space, reducing congestion and creating a more organized workspace.
- Improved Safety: The system-mounted hoist eliminated the need for manual lifting, reducing the risk of workplace injuries.
- Streamlined Operations: The integration of the inventory management system improved material tracking, leading to quicker retrieval times and reduced errors.
- Cost Savings: The automation of storage and retrieval processes resulted in cost savings in terms of labor, space utilization, and reduced material damages.
Conclusion: The successful deployment of the LeanStore automated vertical storage solution with tray extraction and a system-mounted hoist revolutionized the die casting manufacturing industry’s storage and retrieval processes. The highly customized system, combined with the ease of material retrieval and inventory management, significantly improved productivity, safety, and overall operational efficiency. The company experienced cost savings and enhanced customer satisfaction, cementing LeanStore as a crucial component of their manufacturing setup.
