Roark - Aerospace Tool & Die Automated Storage System

Project Overview

Roark, a contract manufacturer specializing in complex sheet metal components for the aerospace industry, faced significant challenges with their manual tool and die storage system. Serving major aerospace customers including General Electric, Rolls Royce, and Pratt & Whitney, the company needed a more efficient and organized approach to managing their critical manufacturing tools. The existing system involved storing tools and dies on pallets along the floor, either in bins or exposed, requiring forklift operations for retrieval and resulting in a disorganized, time-consuming process.

The primary business need was to transform their tool storage from an inefficient manual system to an automated solution that could improve operational efficiency, reduce retrieval times, and enhance organizational capabilities. As a job shop serving demanding aerospace clients, Roark also recognized the value of presenting a professional, technologically advanced image to customers who would be impressed by automated storage capabilities.

Bastian Solutions was selected to implement an automated storage and retrieval solution tailored to Roark's specific needs in aerospace tool management. The project aimed to address both immediate operational inefficiencies and long-term cost considerations in their manufacturing plant.

Technical Solution

Automated Storage and Retrieval System (ASRS)

The core of the solution is an automated storage and retrieval system featuring crane technology that handles the storage and retrieval of tools and dies. The ASRS replaces the previous manual pallet storage method with an organized, automated approach. The system manages tools stored in bins on pallets, with the crane automatically transporting items to and from storage locations based on system commands.

Key Features

The ASRS crane technology provides automated storage and retrieval of tools and dies, eliminating the need for manual forklift operations to access stored items. This automation significantly reduces retrieval times and improves operational efficiency.

Xacta WMS integration enables seamless communication between operator inputs and crane operations. The system supports both manual data entry and barcode scanning for product identification, providing flexibility in how operators interact with the storage system.

The organized storage infrastructure creates a systematic approach to tool and die management, replacing the previous disorganized manual system. This organization ensures that tools can be quickly located and retrieved when needed for manufacturing operations.

The professional implementation and customer-impressive capability demonstrate the system's value beyond pure operational efficiency. The automated storage solution enhances Roark's reputation as a technologically advanced aerospace manufacturer.

The hybrid automation approach combining crane retrieval with forklift interface provides an optimal balance between full automation and practical material handling requirements in a manufacturing environment.

Results & Benefits

The ASRS has significantly improved efficiency in tool and die storage and retrieval operations, eliminating the time-consuming manual search processes that characterized the previous system. Operators can now quickly access needed tools through the automated retrieval process.

The system has enhanced Roark's organizational capabilities and created a positive impression on aerospace customers. The automated storage solution demonstrates the company's commitment to technological advancement and professional operations, strengthening customer relationships.

Long-term cost efficiencies have been established in the manufacturing plant operations. The automated system reduces labor requirements for tool management and minimizes the time lost searching for misplaced or poorly organized tools and dies.

The transformation from disorganized floor storage to systematic automated storage has created a more professional and efficient working environment. Tools and dies are now properly stored and easily accessible, supporting smooth manufacturing operations.

The successful system installation by Bastian Solutions has provided Roark with a reliable, professional storage solution that supports their complex aerospace component fabrication requirements.

Challenges & Solutions

Roark's primary challenge was their manual storage system with tools and dies stored disorganized on pallets along the floor, causing inefficiency and difficulty in locating specific items. The ASRS solution addressed this by implementing an organized, automated storage system with systematic bin storage and crane retrieval.

The time-consuming and ineffective tool retrieval process using forklifts was significantly improved through the automated retrieval system. The integration with Xacta WMS enables quick access to specific tools through scanning or data entry, eliminating the need for manual searching and forklift operations for every retrieval.

The need to improve operational efficiency for demanding aerospace manufacturing customers was met through the comprehensive ASRS implementation. The solution not only enhanced internal efficiency but also improved customer perception by demonstrating advanced organizational capabilities and technological sophistication.

System Integrator

Bastian Solutions served as the system integrator for Roark's automated storage and retrieval project, delivering a comprehensive solution tailored to the aerospace manufacturer's specific tool and die storage needs. The company provided end-to-end services from the initial quotation process through system installation and commissioning.

Bastian Solutions demonstrated exceptional project management throughout the implementation, keeping Roark informed of progress, addressing issues proactively, and maintaining professional standards. The installation was noted as going "very well" with the Bastian Solutions team doing a "very good job" across all aspects of the project.

The successful partnership reflects Bastian Solutions' expertise in implementing automated storage solutions for manufacturing environments, particularly in the demanding aerospace sector where precision, reliability, and efficiency are critical requirements.