Summary: Hi-Tech Extrusions, known for its innovative solutions in custom-engineered thermoplastic profile and tubing extrusions, took an antiquated, labor-intensive coiling process and transformed it into a model of efficiency and sustainability. By introducing larger, reusable wooden reels that hold up to 18,000 feet of material and implementing automatic payoff equipment, Hi-Tech Extrusions not only increased coil run time from a mere 10 minutes to an astounding 22 hours, but also significantly reduced labor costs and material waste for the customer.
Industry: Industrial Manufacturing
Category: Process Optimization and Automation
Processes: Sustainable Wooden Reel Design, Automatic Payoff Equipment, High-Quality Coiling Process
The customer was operating under an outdated coiling process that required frequent changes of small 600-foot reels. This cumbersome task had to be performed manually every 10 minutes, adding to labor costs and inefficiencies. Moreover, the material often crossed over itself during coiling, creating deformities and thereby contributing to additional waste.
Hi-Tech Extrusions went beyond merely replacing the small reels. They designed larger, reusable wooden reels capable of holding up to 18,000 feet of material. Further, they implemented automatic payoff equipment to dispense the product seamlessly into the customer’s manufacturing process. These innovations allowed the product to be consistently coiled to specification and in a high-quality manner.
The new system ushered in multiple benefits for the customer. Coil run time shot up from the tedious 10-minute intervals to an incredible 22 hours. This dramatic increase eliminated the need for constant manual intervention, resulting in significant labor cost savings. Furthermore, the quality of the coiling was improved, reducing the material waste associated with deformities.