Ronnie Sullivan
Member
Just done a straightforward conveyor system for a bedding company.
Nothing difficult (I have done a lot of conveyor systems.)
There are 20, 4M X 2M conveyors in a straight line from the factory to the warehouse.
The operators make mattresses either side of the conveyors and throw them on the conveyor when they have finished one.
Each conveyor will take 2 mattresses....... and this is where the problem started..... each conveyor will take 2 mattresses.
Each conveyor has 2 photo cells - one at the end and one in the middle
If an operator puts a mattress in the middle, it will take it to the end of that conveyor leaving a gap for a second one to be put on. They will then travel on their way to the warehouse.
I get a call that it is not working right and is leaving gaps and he reckons he is 200 mattresses down a per day due to this?
I am now dealing with an irate customer who thinks he is not getting what he paid for.
We are talking - shouting at me.
He shows me the long line of conveyors packed with mattresses all queuing beautifully but with the odd conveyor with only 1 mattress on (The gap he is so angry about)
I tell him that an operator did not put a second mat' on that conveyor. It must have moved on before he had finished.
'you said there would be no gaps'
no, i said you can fit 2 mat's on one conveyor and the system will know where they are and queue them.
He takes me to a gap - this conveyor has one mat' on it. The one in front has 2 and the one behind has 2
'why can't you make it close that gap'?
'because the mat'is at the front and 2 conveyors have to run to transfer from one to the other. It would try to push the front mat' into the ones before it and eventually they would fall on the floor at the end.
'I am 200 mattresses a day down. This system is rubbish.
I say 'Take a look at the unloading end - they cant cope with the amount of mattresses coming down stream - the system is always backing up.
You need another man down there to unload.
By the way - he has taken on a lot more mattress makers but no extra unloading staff. He cannot get his head around the half empty conveyors because someone didn't put one on there.
The mattress are at the unloading end in more volume than they can handle but I am the reason he is 200 mattresses a day down.
Thick!
Nothing difficult (I have done a lot of conveyor systems.)
There are 20, 4M X 2M conveyors in a straight line from the factory to the warehouse.
The operators make mattresses either side of the conveyors and throw them on the conveyor when they have finished one.
Each conveyor will take 2 mattresses....... and this is where the problem started..... each conveyor will take 2 mattresses.
Each conveyor has 2 photo cells - one at the end and one in the middle
If an operator puts a mattress in the middle, it will take it to the end of that conveyor leaving a gap for a second one to be put on. They will then travel on their way to the warehouse.
I get a call that it is not working right and is leaving gaps and he reckons he is 200 mattresses down a per day due to this?
I am now dealing with an irate customer who thinks he is not getting what he paid for.
We are talking - shouting at me.
He shows me the long line of conveyors packed with mattresses all queuing beautifully but with the odd conveyor with only 1 mattress on (The gap he is so angry about)
I tell him that an operator did not put a second mat' on that conveyor. It must have moved on before he had finished.
'you said there would be no gaps'
no, i said you can fit 2 mat's on one conveyor and the system will know where they are and queue them.
He takes me to a gap - this conveyor has one mat' on it. The one in front has 2 and the one behind has 2
'why can't you make it close that gap'?
'because the mat'is at the front and 2 conveyors have to run to transfer from one to the other. It would try to push the front mat' into the ones before it and eventually they would fall on the floor at the end.
'I am 200 mattresses a day down. This system is rubbish.
I say 'Take a look at the unloading end - they cant cope with the amount of mattresses coming down stream - the system is always backing up.
You need another man down there to unload.
By the way - he has taken on a lot more mattress makers but no extra unloading staff. He cannot get his head around the half empty conveyors because someone didn't put one on there.
The mattress are at the unloading end in more volume than they can handle but I am the reason he is 200 mattresses a day down.
Thick!