Just-In-Time Conveyor System Unloads 53’ Trailer in Under 1 Minute

May 12, 2022 | Chain Driven Live Roller, Conveyor Systems, Trailer

When a trailer leasing company for a large automotive seat manufacturer needed a just-in-time delivery conveyor system, we were up to the challenge. During initial conversations with the customer, it was clear that unloading products in the most expedited, efficient manner was a mandatory requirement by the end user. Power Pack was up to the task, as designing complex conveyor systems is at the core of Power Pack’s value proposition.

About Just-in-Time (JIT) Delivery

In the automotive industry, all supplier deliveries are time-sensitive and critical from both operational and financial standpoints. Most contracts will include a penalty clause that charges excessive fees, often times on a per minute basis for any delays. In this case, a Just-in-time delivery was required on a repeated basis multiple times per day.

Just-in-time (JIT) delivery aligns with the JIT inventory management strategy that matches orders from suppliers with production schedules. Automotive manufacturers use the JIT inventory strategy to increase efficiency and decrease waste by receiving goods only as they need them for the production process, which reduces inventory costs.

Instead of ordering stock in bulk, with JIT delivery, businesses order their stock on an as-needed basis to keep inventory levels lower. This process is designed to drastically increase efficiency and decrease waste. JIT delivery also reduces inefficient labor costs by allowing employees to allocate their time to production rather than unpacking and storing inventory that may sit for an extended period.

Initial Planning

During the planning phase, our engineers met one-on-one with the client to discuss the exact needs, specifications, and turn-around time for this delivery system. The turn-around time for this delivery is less than 30 minutes from the seat manufacturer to the auto plant. The reliability of the conveyor operation is critical, again, as any downtime can result in considerable financial penalty. So far, the turn-around time has been met consistently.

We spent countless hours with the customer finalizing the design, keeping in mind the numerous requirements of this project: Improving efficiency, reducing labor costs, better functionality, and sustained reliability. Our engineers worked with the customers’ engineers to understand all aspects of the specs for daily product deliveries. Such details include product quantity, size, weight, transport, as well as the loading & unloading processes. Next, we developed 3-D renderings to help collaborate with the client, adjust our approach, and document our final plans.

From Design to Final Solution

Taking all details into consideration, we created a two-level chain conveyor system designed to unload the full trailer in less than one minute and easily transport the empty pallets back to the supplier. Our design accomplished the project requirements and has since been replicated in over a dozen trailer conveyors for the same operation.

The Power Pack Trailer Conveyor systems are so well-constructed that they typically have longer life spans than the trailers themselves. We have removed these trailer conveyors from worn-out trailers and reinstalled them in new trailers.

The trailer conveyor is a huge time saver over loading and unloading manually. The cycle time is predictable allowing for efficient just-in-time deliveries. These high-quality, low-maintenance, heavy-duty conveyor systems reduce labor costs, help our clients avoid late fees, and creates a positive return on investment.

This is just one of many types of trailer conveyors we can design and manufacture. Trailer conveyors can be used for other automotive products such as tires, transmissions, instrument panels, and truck cabs or in other industries including consumer goods and appliances.

Power Pack is a manufacturer of engineered conveyor systems, dedicated to providing access to technical support, high-quality craftsmanship, and industry-leading lead times.

Have a just-in-time delivery challenge? Contact Power Pack to discuss your project.

About the Author

Dan Farrar is the CEO of Power Pack Conveyor Company, a pioneering industrial conveyor manufacturer since 1929. Power Pack Conveyor Company specializes in designing, engineering, and manufacturing conveyors, conveyor components, and turn-key systems for OEMs, System Integrators, and Distributors.

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