“Order, Storage, and Retrieval” (OSR) - System Alignment and Setup Jigs
Advanced IndustrialEngineering Ltd were awarded a contract to design, manufacture, and commissiona suite of alignment and setup jigs for an “Order, Storage, and Retrieval”(OSR) retail distribution system.
Overview
Advanced Industrial Engineering were approached through a third party to quote an RFQ for the supply of a set of shuttle alignment and setup jigs at one of the most complex retail distribution partners in the UK.
The new equipment was required for the customer’s “Order,Storage, & Retrieval” (OSR) system to support more efficient and consistentservicing work.
The sales team reviewed the technical information provided by the customer and submitted a detailed technical proposal, including 3D design concepts and full cost breakdown.
Background
The customer was a large retail distributor with millions of order lines moving weekly, zero tolerance for downtime, and constantly evolving product and process requirements.
The customer’s retail distribution site had three “OSR” systems. Each system had slightly different configurations; therefore, the new shuttle jigs would need to be tailored to the individual system that they support.
Each “OSR” variant shared similar functional requirements but in turn required a bespoke jig solution due to differences in layout and configuration.
To fulfil the customer’s requirements, the right engineering partner was needed to ensure a successful project outcome.
After reviewing all of the submitted technical proposals, Advanced Industrial Engineering were successfully awarded the contract.
Challenges, Constraints and Success
The existing customer setup utilised a range of basic jigs for wheel and sensor alignment of the transfer shuttles, alongside a legacy maintenance platform (some are shown below).
The customer requested that these existing elements be reviewed for a potential upgrade to support more efficient and consistent servicing work, including planned preventative maintenance (PPM) by the maintenance department.
The customer ideally wanted the PPM work to be a focused andscheduled activity rather than a reactive breakdown situation where possible.
In principle, two distinct jig types were required:
1 - Shuttle in “removed position”
To be used primarily during planned preventative maintenance(PPM), this jig would enable consistent and accurate setup of shuttle mounted components such as sensors, drive wheels, and alignment features.
2 - Shuttle in “racking position”
Designed for use during both PPM and reactive maintenance, this jig would support standardised alignment between the shuttle and the racking infrastructure, particularly focusing on sensor positioning and interface tolerances.
A successful project for the customer would be seen with thefollowing activities performed, (1) safe and effective introduction of newequipment with minimal disruption to existing production, (2) adoption of thenew jigs by the maintenance department supporting more (3) efficient andconsistent servicing.
Technical approach / Methodology
The Advanced Industrial Engineering technical proposal wasmade up of the following items:
(1) 1 x Conveyor Setting Frame
(2) 1 x YOSR Shuttle Setting Jig
(3) 1 x OSR32 Setting Jig
(4) 2 x OSR35 Shuttle Sensor Setting Jig
The solution included:
• Full 3D and 2D design, signed off for manufacture by all parties.
• Integration with existing docking stations onsite.
• Factory Acceptance Testing (FAT) at Advanced Industrial Engineering’s facility with the customer present.
• Delivery, installation, and commissioning at the customer’s site.
• On-site operator training following successful SiteAcceptance Test (SAT) sign off by the customer.
• Full certification and supply of project technicalfile including operator and maintenance instructions, TPM schedule, spare partslist, BOM, DRAs, DFMEA, load test certification, 3D STEP files, GA drawings,and safety guidance.
All the equipment was supplied and certified to the latest regulatory standards with the correct technical documentation provided.
Implementation
Following receipt of a customer purchase order, Advanced Industrial Engineering begin the design process. All parties were engaged in the review process of the proposed solution maintaining close customer engagement at every stage up to sign off.
Once achieving design sign off, purchase, manufacturing andassembly could then begin.
Factory Acceptance Testing (FAT) was carried out in the Advanced Industrial Engineering workshop with the customer, where changes or upgrades were recorded and implemented prior to shipping the finished equipment to the customers site.
On site Advanced Industrial Engineering’s installation team managed the commissioning process, including a final Site Acceptance Test (SAT) confirming that trolleys located correctly and that the interaction with fixture performed as designed across all units.
Setting frame processes improvements
The existing setting frames were reworked to include new location mounts and laser sensors targets for position checking. In addition, new sensor plates were added to the frame for checking and setting the height of the shuttle when passing around the transfer conveyor system.
YOSR Shuttle Setting Jig
Advanced Industrial Engineering’s concepted a shuttle setting jig made up of a jig table, tooling, rollers and modifications to the existing scissor lifts.
Conclusion
Using processes and procedures honed on automotive projects, Advanced Industrial Engineering’s proved that they could apply them to other industries successfully.
The solutions provided, met the requirements outlined by the end user, the delivery and support was performed to the highest ability from the onsite team at Advanced Industrial Engineering’s, timing and budget were maintained.
From Concept to Commissioning.
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