How we run a new project
One example, from the first walk-through to handover: where material got stuck, what we proposed, and what we built.
On the first day we walk the plant.
We follow the material from goods-in to dispatch and talk to the shift leads and the forklift drivers. They know best where the work usually gets held up.
On to the surveyWe map how the material moves.
We map every forklift route and every trip made by hand. The material flow map shows where routes cross and where parts travel further than they need to.
On to the bottleneckPallets pile up in front of assembly.
Pallets wait in front of the assembly line, the forklift has to queue, and parts are lifted across by hand. This is where most time can be saved.
On to the proposalOur proposal: an overhead conveyor above the aisle.
The track carries parts from machining to assembly above the aisle, alongside the existing columns. We agree the route, the load and the cycle time on the drawing, and the quote follows from it.
On to the buildWe build and install it.
We make the supports and the track in our own workshop and split the installation into stages, so production can keep running. Once the carriers start, the pallet queue in front of assembly is gone, and so is the lifting by hand.
On to handoverHandover and training
We commission the system, hand over the documents and train the operators. You can count on us later for maintenance or extensions too. The project shown is a made-up example; the way we work is real.
Four phases of a project.
Each phase ends with something you can use, and then you decide whether to go on.
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Walk-through and survey
A day in your plant: we follow the material, measure distances and waiting times, and note the constraints.
- Material flow map
- Site measurements and photos
- The one bottleneck that matters most
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Concept and quote
We sketch two or three options, each with a route, a load rating and an estimated cycle time. We quote the direction you choose.
- 3D layout
- Options compared
- Itemised quote and schedule
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Design and fabrication
Detailed 3D model, strength checks and shop drawings. We fabricate and trial-assemble the steelwork and mechanical parts in our own shop.
- Shop drawings
- Surface treatment and powder coating
- Trial assembly in the shop
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Installation, handover, service
Staged installation next to running production, commissioning and training. We stay on afterwards: maintenance, extensions, changes.
- Manual and CE documents
- Operator training
- Maintenance agreement
Where does material get stuck in your plant?
We start with a walk-through, then tell you what we suggest and what it costs.