Cooper B-Line Achieves Significant Productivity & Ergonomics Gains with New Conveyor System

Cooper B-Line Inc., an Illinois-based manufacturer of electrical, mechanical, and telecommunication supports, has successfully implemented a new conveyor system at its Reno, NV manufacturing facility, specializing in racks, runway, and related component kits for the telecommunications industry. This upgrade has led to substantial improvements in productivity, efficiency, and ergonomics compared to their previous manual handling processes.

Previous Challenges: Manual Handling and Forklift Dependence

Before the installation of the new system over a year ago, the Reno facility lacked any conveyor materials handling equipment. Operations relied on building loads directly on the floor and moving everything using forklift trucks. As Matt Emerson, Cooper B-Line’s facilities engineer, recalled, “Basically, we were building loads on the floor and moving everything around by forklift truck. After we built a pallet load, we would have to wait around for a forklift and driver to move it before we could start working on the next order.” This ¹ dependence on forklifts created bottlenecks and limited the speed at which orders could be processed.  

The Solution: Integrated Conveyor System

The new material handling system at the Reno facility is a hybrid solution, incorporating standard conveyor equipment from Hytrol and a customized unit from FloStor. This integrated approach was designed to streamline order flow, minimize manual handling, and improve the overall efficiency and ergonomics of the operation.

Material now flows more efficiently, with forklifts and transfer carts bringing telecom racks and runway to packing stations located next to the main conveyor lines. Assemblies are stacked onto pallets resting on drag chain conveyors at these stations. These loads can be substantial, typically stacked four feet high and weighing over 1,000 pounds.

Once a pallet is built, chain transfers automatically move the load onto the main takeaway conveyor line, a Hytrol Model 25-CRR chain-driven live roller designed for handling loaded pallets. This eliminates the waiting time previously associated with forklift availability.

The system includes different pathways for orders. Standard, high-volume orders proceed through a banding machine and then to an order-accumulating conveyor, a drag chain unit with a module to prevent pallet-to-pallet contact. Orders requiring crating are also banded but then move to a specialized crating station designed by FloStor. This custom unit acts as a combination of a transfer cart, lift table, and conveyor, allowing the pallet load to be moved offline and elevated. This elevation is crucial for workers, enabling them to crate and secure the load safely and efficiently without excessive bending or manual handling. After crating, the load is transferred back to the main takeaway line for accumulation or additional banding if needed.

Realized Benefits: Higher Throughput and Enhanced Ergonomics

The implementation of the new conveyor system has yielded significant benefits for Cooper B‑Line:

• Higher Throughput: The facility has seen a 30 to 35 percent greater throughput level compared to the previous manual system. According to Matt Emerson, the Reno facility now averages about 150 racks per line in an eight-hour shift.
• Increased Flexibility: The system’s design allows for different handling requirements for various order types, adding flexibility to the operation.

• Less Manual Handling: The automated transfer and movement of pallets significantly reduce the need for manual lifting and carrying.

• Reduced Dependence on Forklifts: The conveyor system handles the movement of pallet loads from packing to accumulation, lessening the reliance on forklifts and their operators for this task.

• Enhanced Load Security: Operators have better control over pallet positioning during the banding process, resulting in more precise banding and improved load stability.

• Improved Ergonomics: The heavy-duty chain transfers move loads effortlessly, and the adjustable crating stations allow workers to perform crating and securing tasks with minimum bending and maximum access to the load, reducing physical strain.

In conclusion, the new conveyor system at Cooper B-Line’s Reno manufacturing facility has proven to be a successful investment, leading to a more productive, efficient, and ergonomically friendly operation that benefits the company, its workers, and its customers.