At Cordstrap in Oostrum, everything revolves around securing and protecting loads worldwide. As a manufacturer of load securing solutions, reliability is crucial in all logistics processes, including internal logistics. With the increasing shortage of personnel and the desire to automate repetitive tasks, Cordstrap chose to use a Pallet Jack AGV and Pallet Dispenser Basic line from KUMATECH.
We spoke to Jan Gijsbers, Technical Coordinator Maintenance at Cordstrap, about the reasons behind this decision, the process and their initial experiences.
Why automate
Cordstrap is a total supplier of load securing solutions. Many products are manufactured at its own production sites, including in Oostrum, Limburg. Cordstrap continuously works to achieve competitive advantage for its customers. Given wage developments and the limited availability of production personnel, the automation of production and logistics processes at the Dutch factory has been a clear focus for several years. Two years ago, for example, the company decided to automate production, packing/palletising and internal transport of pallets. Operators are now less involved in repetitive tasks and can focus more on monitoring quality and output.
Cordstrap quickly decided on an AGV or AMR for the automation of internal logistics. “We want our production lines to run as autonomously as possible. That starts with eliminating repetitive, simple movements.”
Choice for KUMATECH
An important requirement for choosing an AGV or AMR was that it had to be able to handle the weight. “We deal with heavy loads, and not every AGV or AMR can handle that. We also wanted a regional supplier that was competitively priced.” The system had to be robust, reliable and not too complex. “That’s how we ended up with KUMATECH, because of the total picture. The contact with Willem, John and the technical service went well, and that gave us confidence.”
To complete the automation of the process, including the supply of empty pallets, a Pallet Dispenser Basic line was also chosen: “A nice addition that works well together.”
Implementation
During the tour through the factory, Jan shows where the Pallet Jack and Pallet Dispenser are operational. Buckles are produced on the production line, packed into boxes by a cobot and placed on pallets. The Pallet Jack ensures that an empty pallet is ready, which it retrieves from the Pallet Dispenser itself. Once a pallet is full, it is picked up by the AGV (controlled via the app) and taken to storage.
The implementation presented a number of challenges. “We had some start-up problems, including with WiFi coverage and the floor. As a result, it took a little longer for the AGV to become operational, but now it is running smoothly.”
The collaboration with KUMATECH remained positive. “Communication was good, we were able to switch quickly and they really thought along with us.”
Employees had to get used to it, but they see the benefits
As with any change, there was some doubt at first, but there was no real resistance. “It was mainly a matter of learning how to use the system and getting to know the process. Once you understand what the device does, you quickly realise that it really takes work off your hands and allows you to do more enjoyable work yourself. Guidance is therefore very important here,” emphasises Jan. “Controlling it, pressing the buttons, that took a bit of extra caution, due to a bit of fear/reluctance. That’s going well now.”
First results and future plans
“We are already seeing returns from this part of the process,” says Jan. “We are saving a lot on walking movements, and a lot of lost time is being recouped by the AGV. The time savings may seem small, a few minutes here and there, but on an annual basis it adds up to quite a lot.”
The calculation? “Take, for example, 40 pallets per day, each requiring 5 minutes of handling, 6 days a week. That’s a significant amount of time that is freed up for other work.” The ROI was calculated for this part alone, but there are certainly plans for the future. “Ultimately, the intention is to expand this route and also deploy an AGV in other departments.”
“The investment simply pays for itself. Not in AGV time, but in operator time, that’s where the real profit lies.”
Finally. Tips?
“Don’t be afraid of the investment, it will pay for itself. Not because the operation is necessarily faster than when an employee it does, but because you save time structurally. Time in which an operator would otherwise not be productive. You take repetitive work away and create space for tasks with more value. Automation is not always faster, but it has to be smarter.”