The purpose of the installation is to cover meal trays and place them in airplane trolleys fully automatic.
Capacity and flexibility are two key words here. The installation has be able to process an average of 30,000 meals per day. In addition, the customer wants maximum flexibility with a system that can process different types of trays and place all kinds of products with different shapes on it.
We set out various scenarios based on the drawn up guidelines. Then, with the expertise of both parties, we make the puzzle work. The concept results in a dynamic, modular installation with four intermediate buffer areas in strategic places to absorb any delays.
The dynamic, modular concept translates into dividing the workflow into four critical phases: the supply of raw materials, assembling the trays, placing the trays in the trolleys and buffering these phases.
Working with intermediate buffer area gives an extremely big advantage. If a temporary problem occurs in one of the units, the previous units can continue to run. The use of these buffer areas creates a harmonica movement that can prevent a general standstill.
The ERP system from KCS indicates which type of meal should be placed where in the trolley. This information is translated into a code that enables the robots in the assembly line to place the right products in the right place on the tray. This is controlled by a vision system.
The new assembly line is one of the most modern and innovative in the world and can process up to 36,000 meals per day.