One-liner: Concept, sizing, and evaluation of an automated material handling system with layout alternatives, sensors, buffers, and KPI-driven throughput analysis.
Situation
The post-processing line required higher, stable throughput while avoiding overload at critical stations.
Task
Design an automated material handling concept that reaches ~90 bars/hour and improves flow reliability via the right combination of conveyors, diverters, sensors, and buffer sizing.
Action
- Developed and compared multiple layout alternatives (flow paths, merge/divert logic).
- Selected handling components (conveyors, diverters, accumulators) and placed sensors/inspection points.
- Calculated machine counts, waiting elements, and buffer capacities; analyzed utilization and throughput.
Result
- Target throughput (~90 bars/hour) achieved in the selected concept.
- Reduced risk of bottlenecks by keeping critical machines below 100% utilization.
- Clear sizing rules for equipment and buffers to support reliable operation.
Figure 1: Final system layout with main stations, central conveyor, and buffer zones
Figure 2: Handling Subsystems — Layout 1 illustrating diverters, conveyors, and buffers for automated material flow
Figure 3: ⚡ Power Calculations — Dimensioning of conveyors, accumulators, and diverters performed in SMath Studio
Key takeaways:
- System throughput validated at ~90 bars/hour.
- Buffer capacity sized to stabilize flow and reduce machine overload.
- Power requirements calculated for conveyors, accumulators, and diverters to confirm feasibility.