Bastian Rolls Out a Labor Reducing Solution at APP St. Mary’s

AAP St. Mary’s

System Overview:

For more information, visit bastiansolutions.com or call (800) 772-0464

A division of Hitachi Metals, Ltd., AAP St. Mary’s is a supplier for Honda, Ford, Subaru, Nissan, and Toyota. AAP produces wheels from 15” to 22” in diameter.

The AAP system consists of a large, mezzanine installed conveyor network using about 3700 ft of zero pressure accumulation conveyor, 15 aisles of AS/RS buffer providing about 15,000 storage locations for WIP wheels, control systems and inventory systems that manage the process. The primary purpose of this system is to move wheels efficiently between casting, paint and machining with no human con-tact with the wheel. Phase 1 of the project installed about half of the conveyor and the western buffer. Phase II will complete the project.

System Overview:

AAP St. Mary’s

For more information, visit bastiansolutions.com or call (800) 772-0464

Business Challenges:• AAP was searching for a method to streamline and synchro-

nize the flow of wheels between various operations.

• AAP wanted to reduce employee turnover and associated

training costs, and lessen the manual labor requirements for

handling each wheel.

• Forklift traffic was dangerous and needed to be reduce or

eliminated.

• Visibility of inventory and system capacity needed to be

improved.

• Scheduling and inventory locators existed as hand-written

notations on loose paper.

Key Technologies:• 15 aisles of Daifuku AS/RS buffers providing about

• 15,000 storage locations for WIP wheels, controls systems,

and inventory systems.

• 3700 feet of chain driven 24v Motorized Drive Roller

• Bastian Controls Warehouse Control System (WCS)

• ASAP Automation Warehouse Management System and AS/

RS Controller

• Cognex/Integro vision system

• Bastian Solutions custom lifts

Results:• AAP St. Mary’s manual labor requirements were significantly

decreased.

• Fork lift traffic was safely reduced.

• Inventory and quality control improved.

• The project’s success has greatly improved AAP’s ability to

succeed in a very competitive industry.

• Bastian has been asked to partner with AAP on future growth

phases.

Bastian Rolls Out a Labor Reducing Solution at APP St. Mary’s