50% Throughput Boost Secures Success for Snap-On

Challenge: Optimize current labor-intensive process.

Snap-on’s assembly line initially relied on a 25-foot gravity conveyor system. Workers had to manually push crates and pallets, each weighing between 350 and 500 pounds, along the conveyor. This labor-intensive process posed ergonomic problems and delayed operators’ return to their stations, leading to decreased productivity.

Chase Wykes, Automation Engineer at Snap-on, described the situation:

“Operators would load the pallets using their roller carts then have to push with brute force up to 10 pallets at a time.

This was an ergonomic issue to our operators and greatly delayed them returning back to the stations since they were required to move the product once on the conveyor.”

The gravity conveyor’s minimal slope exacerbated the problem, making it difficult for workers to push the heavy pallets and crates along the assembly line. This process was physically challenging and hindered overall operational efficiency.

Solution: Fully automated with Hytrol accumulation conveyor.

To address these issues, Snap-on collaborated with AEC and Trace Davis to design and implement a more efficient and safer conveyor system.

Trace proposed using the Hytrol model 25-CREZD, an advanced chain-driven live roller accumulation conveyor. This system featured Hytrol’s EZ-Logic accumulation technology, which uses photo eyes and built-in logic for zero pressure accumulation, eliminating the need for manual pushing.

Trace Davis explained the advantages of the new system:

“By adding a Hytrol 25-CREZD conveyor, we were able to eliminate the need for workers to push crates from station to station.

The EZ-Logic accumulation system ensures smooth and efficient movement without requiring a PLC.

Safety was also a big key in this project, so we incorporated emergency stop pull cables, illuminated emergency stop buttons, and body-sensing light curtains to protect operators.”

The new conveyor system allowed operators to load a single pallet or crate and simply walk away, freeing them to return to their assembly stations promptly. This automation significantly reduced the physical strain on workers and improved overall productivity.

Safety enhancements, such as emergency stop pull cables, illuminated emergency stop buttons, and body-sensing light curtains, ensured a safer working environment.

Chase Wykes praised the solution and the collaboration with AEC and Trace Davis:

“AEC helped us identify a solution that would be affordable for us and satisfy all our needs. Trace Davis has been excellent. He is an effective communicator and ensures his customers’ questions are answered.

His dedication to seeing the project through to completion, even requiring a weekend trip away from home, was impressive. You can tell he enjoys his work and making his customers happy. Service like that keeps customers returning!”

Result: 50% Throughput Boost, Increased Efficiency, and Enhanced Safety

The implementation of the Hytrol 25-CREZD conveyor system resulted in several key benefits for Snap-on:

Improved Ergonomics: The automation of the conveyor system eliminated the need for manual pushing, reducing the physical strain on workers and minimizing ergonomic risks.

Increased Efficiency: Operators could quickly return to their stations after loading pallets or crates, leading to a more streamlined and efficient assembly process. This results in an estimated 50% increase in throughput.

Enhanced Safety: The addition of safety features, such as emergency stop mechanisms and body-sensing light curtains, ensured a safer working environment for all employees.