Just-in-time project for Toyota Motor Manufacturing

Just nine weeks after the order was placed, seven new KZV-311-14 strapping machines were installed at the TMMF plant in Valenciennes, France.  The machines have been operating perfectly to replace the old system, in which pallets were tied manually.

It all started at CEMAT 2016. A senior management representative from Toyota Motor Manufacturing France visited the trade show in search of a new solution for securing pallets with empty containers. The company hadn't used a strapping system in the past, but knew exactly what it wanted: seven machines set up in a line capable of strapping pallets simultaneously.  

In the past, TMMF manually secured pallets - stacked with empty containers - for shipping with bands. This packaging method was relatively laborious, but didn't take up much space in the factory. Along with other requirements, the new system would have to be configured for space-saving integration into the plant. Seven pallets loaded at different heights would have to be strapped simultaneously in one operation. The biggest challenge was the tight project deadline: after the contract was signed, there were only nine weeks to deliver the fully configured system.

A new strapping system

None of Mosca’s existing strapping systems met the requirements specified by the customer. Therefore, a project team - made up of members from different departments - created a concept for a customized system with seven KZV-311-14 strapping machines. A fully automated vertical strapping machine was developed with patented SoniXs ultrasonic sealing units for securing different sized packages. It can be integrated into production lines with an optional conveyor system (although this was not required in the installation at TMMF). The operator drives through the open strapping frames with a conveyor vehicle that pulls seven wagons loaded with pallets. A light signal shows the operator when the conveyor vehicle is in the correct position in front of the barrier. Using the panel on the side of the machine, the operator starts the strapping process for the seven pallets stacked at different heights. After the strapping cycle, the barrier lifts and the operator exits the system with the strapped pallets. The entire process takes around 80 seconds and is much faster than the company's previous system.

Outstanding teamwork

In the nine weeks that followed the contract being signed, the bespoke concept was developed, machines were built and networked electronically, plus reference documentation for the completely new system was written. Throughout all stages of the project, Mosca maintained close contact with Toyota Motor Manufacturing France. The collaboration allowed for quick responses to suggestions for optimising the installation and enabled a system that was perfectly tailored to the application.  After-sales service coordinated by the sales department in France was a key factor for the car maker enabling Mosca’s specialists to carry out routine maintenance on-site and quickly respond to emergency service requests.

A concept with future potential

Mosca were delighted by the successful completion of this just-in-time project which got the teams looking to the future: The new system represents the development of a new application environment for strapping. This system, or a modified version of it, is ideal for other automotive manufacturers or suppliers who need to strap pallets under similar conditions. At the same time, it can be efficiently used by logistics companies across all industries.