Test Conveyor System - Home Appliance Manufacturer

PROBLEM: Operators were manually loading appliances on carts and pushing them to a test area. After testing, the carts were pushed back to the assembly line or to repair. Our customer needed a solution that decreased the amount of manual handling involved in the process, and increased the throughput of the system.

SOLUTION: ABCO's Engineering Services Department worked with the other departments of ABCO, outside vendors and contractors to provide a turnkey solution. A Test Loop System was designed in conjunction with the customer and ABCO's other departments to make the process of testing appliances more efficient. The system consists of two major components - a conveyor system and the Test Loop itself. Project Managers from ABCO worked with the customer to write functional specifications, equipment specifications, and subcontractor scope of work.

The installation occurred in two phases to minimize interference with the ongoing plant production. The test loop conveyor and the majority of the assembly line interface conveyor were installed and tested first. The remaining interface conveyor sections (which attached to the assembly line) were then installed and tested over a weekend. The assembly line then resumed production on Monday with no downtime as a result of the installation. ABCO provided on-site support throughout the installation and startup. ABCO also provided operations and maintenance training as well as complete documentation for the system.

SYSTEM DESCRIPTION: The conveyor system facilitates the transfer of appliance between the assembly area and the Test Loop. It also has provisions for rerouting appliances that need repair. The operation of the conveyors is fully automated. Appliances are transferred to and from the Test Loop by a transfer conveyor that matches speed with carriers on the Test Loop and rolls them onto and off of carriers automatically.

The Test Loop System carries the appliances through the test process. The Test Loop consists of an overhead conveyor (approximately 80 feet long) arraigned in an oval, thirty-one carriers (each with a capacity of approximately 800 pounds), an oval water trough, and various pumps and valves. The overhead conveyor is chain driven, and moves the carriers around the loop at a preset, adjustable speed. The carriers supply heated water, and electrical power to each appliance being tested.

ABCO received an Outstanding Vendor Award from for our quality and service.