 20% Productivity Gain From KFA Productivity gains of 20% or more have been achieved through the use of KFA's component loading systems. Not only can operators suffer less stress and greatly reduced load lifting demands, allowing them to use their time more effectively, but manufacturing and process systems experience less down time, enhanced accuracy and greater throughput. This is the consistent experience of current users of the range of automatic loaders, vibratory feeders and screen systems who keep coming back for more because they are so pleased with the results.
Textron
Take for instance Textron Fastening Systems Ltd, the specialist manufacturer of high quality components for the aerospace and automotive industries and part of Textron Inc. the US$ 11 billion industrial giant. Recognising their need to improve productivity and meet ever more stringent health & safety requirements, Textron created "blitz teams" to identify opportunities for significant improvement. One element common to many of their production processes in the was the separation of bulk batches into discrete items so that they could be properly fed to succeeding process stages.
Wisely, they called in KFA to advise and develop effective solutions and to date KFA have supplied more than 35 units, each tailored to specific system requirements. These include high level tipper units, hydraulic decanters and multistage vibratory feeder-spreader systems, all of which were entirely designed and built at KFA's Redditch factory. So pleased are Textron with the performance of the equipment that more are on the way to fit in with their continuing improvement programme.
High Level Tote Pan Tipper Units
These floor standing units take multiple batches of components in standard tote tins from low level and lift them, under sequential control, to empty the contents into a high level storage hopper. From the hopper, using electro-mechanical detectors to sense demand, components are discharged at a controlled rate via a vibratory feeder to load second and third operation machines such as thread rollers and automatic assembly systems. The new equipment has not only eradicated down time from component jamming, a frequent occurrence with the old belt elevator system, but also eliminates the potential for operator injury from lifting weighty containers.
Hydraulic Decanters 
From the company's high speed production processes, components are held in 12 cu ft box pallets or special stillages from which they must be divided into a variety of standard containers for subsequent processes. In the Decanter units, the stillages are gradually rotated and emptied in a controlled manner into vibratory feeders which use ultrasonic or electronic sensors to control the discharge of specified quantities or weights of components, ensuring compliance with quality and production parameters. Some of the systems are designed for use with components leaving the heat treatment line at elevated temperatures and incorporate heat resistant surfaces to ensure long life even in a hostile environment.
Vibratory Feeders
Textron use a combination of KFA's hydraulic tipper units and high capacity vibratory feeders to supply components to their washer lines and heat treatment furnaces. These units have hydraulic tipper systems which can readily handle the company's 1 tonne capacity wheeled storage bins, emptying them into bulk receiving hoppers. In the washer feeders, baskets automatically reach the feeder discharge point and trigger the feed system. An ultrasonic sensor causes the feed to stop at a pre-set level and the full basket is transferred to the washer unit. The furnace loaders incorporate twin vibratory feeders, the first of which is controlled by a volume sensor in the second unit. This second feeder can be set to spread components across a continuous mesh belt which carries them through the heat treatment tunnels. An accurate and even discharge rate can be achieved using various control methods.
Textron experience the benefits
In every way, Textron have benefited greatly from their association with KF Alliance Engineering, that's why they know that investment in KFA equipment gives an effective return. Typical comments from managers in the production departments include "Productivity (gains) are restricted by process time, still a 20% increase has been achieved," and the KFA loaders have "eliminated manual handling from the process" and given "a reduction in labour required to run the plant, allowing extra plant to be run by the same operator." Textron are not alone in reaping these rewards.
These benefits are now available to you
One of the great benefits from dealing with KFA is that they have the expertise to identify the key requirements for any handling or feed system. They are used to being presented with a problem, sometimes by companies who have attempted unsuccessfully to solve it themselves, and to finding a reliable solution which provides both direct economic and indirect advantages. All KFA's products have safety interlocks and guarding as part of their design, not as afterthoughts, so that customers can be assured they are buying a complete solution, not one that will bring further headaches!
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