This Warehouse Conveyor System Is a Game-Changer for Apparel Industry Manufacturer

Company Overview

Robinson Manufacturing specializes in apparel design, manufacturing, embellishment, warehousing, and distribution services. They offer a full range of services to support the apparel industry, from creating designs to managing warehouse operations and the logistics of getting products to market. Their headquarters are in Dayton, TN.

Their Engineering Director, Matt Long, worked with Dynamic Conveyor in the past when at a plastics injection molding company who had a challenging need and bought conveyors from the equipment manufacturer. This started Matt’s loyalty for Dynamic Conveyor equipment that carried over to his role at Robinson Manufacturing. 

The Challenge

The process of moving apparel products from picking to manifesting stations was all manual. Workers boxed picked items, carried them to the manifesting station, unpacked the boxes for embellishment and then boxed them again to transport to shipping. This manual process was very labor-intensive, it capped throughput and was physically demanding for workers. Robinson Manufacturing needed an automated process to move apparel items between fourteen process stations. 

The Solution

After providing a concept to Dynamic Conveyor’s sales representative, Dynamic Conveyor provided a conveyor system solution with a drawing that proposed modular conveyors DynaCon and  Hybrid Specialty Conveyors with integrated controls that move items from the picking station to the manifesting location. The system includes photo eyes to detect when a worker at a station has completed the embellishment of a product and automatically moves new product forward allowing workers to remain at their stations ready to accept the next product. 

Results

Ending the need for workers to pack and unpack products into boxes to transport materials has increased throughput by 200% and has made for a happier and safer workforce. This investment in a conveyor solution including smart material handling equipment not only boosts productivity but also improves ergonomic conditions for workers. The warehouse automation package was set up to ensure that items moved from the picking station to embellisher station without workers having to handle the product. 

Since 80% of the company’s business is done between Black Friday and Christmas, Robinson Manufacturing needs to be able to adjust the conveyors for the changing volume and types of products that move through in peak order fulfillment and softer business seasons. The modular conveyor design allows the company to adapt the conveyors for different product processes as needed. “It is so easy to reconfigure, a kid can do it,” Matt said. Dynamic Conveyor’s Controls Engineers have set up and taught Matt’s team how to adjust controls for product changes and volume to be done onsite as workflow requires. 

After several years in place running 24/7 Matt says no maintenance has been needed on any of the conveyors. When the time comes Matt knows from experience that worn replacement parts are quick and easy to access from Dynamic Conveyors’ Customer Support center. 

The conveyor solutions from Dynamic Conveyor have gained Robinson Manufacturing significant energy savings. Matt shared that other conveyors come with high horsepower motors that are overkill for what Robinson Manufacturing needs and includes high energy costs. The company’s products do not require high horsepower to transport.  Dynamic Conveyor’s equipment includes high efficiency motors resulting in low energy consumption and they work well for the products being moved. 

“These modular conveyor systems are a good product, with a long lifespan, low energy consumption and easily adapt to our frequently changing operation,” said Matt. “I’ve ordered another conveyor system for another area of our plant.” 

Ready to improve efficiency, reduce labor strain, and future-proof your warehouse operations? Contact Dynamic Conveyor to learn how our modular material handling equipment can transform your workflow.