Knoll Mfg., a leading office furniture manufacturer based in East Greenville, Pennsylvania, is renowned for producing "exciting, mature, and long-lasting" office furniture. The company has consistently focused on innovation and modern design, which has led to significant advancements across various product categories, including office systems, chairs, archives, storage solutions, workbenches, desks, wooden boxes, textiles, and accessories.
Recently, Knoll introduced a new material handling and order tracking system specifically for its office chair product and packaging line. This upgrade has dramatically reduced cutting costs, eliminated order processing errors, and accelerated the shipping process. The system integrates RFID technology, barcode scanning, Accu-Sort Systems equipment, new conveyor belts from Stokes Material Handling, and software and controllers from BP Controls. It operates within Knoll’s production facility in East Greenville, where four office chair production lines manufacture popular brands such as Chadwick, Life, RPM®, and Bulldog®.
To ensure accurate tracking, each assembled chair, wrapped in protective film, is placed in a reusable tray equipped with an RFID tag. These tags are encoded using an RFID write/reader, allowing the system to identify and track each unit throughout the factory. Previously, manual labeling was used, which involved attaching labels with shipping details like order numbers, destination codes, and quantities. After labeling, chairs were either wrapped or placed into shipping boxes and transported via pallets to one of three stock centers located approximately 1,000 feet away. This process created challenges, including forklift maintenance, fuel costs, and safety concerns, as well as the risk of incorrect shipments.
To address these issues, Knoll partnered with Stokes Material Handling to implement an automated material handling system that identifies chairs by order number, purchase number, and destination, automatically sorting them into the correct areas and directing them to the right loading gates. The system uses advanced conveyor belts, automated lifts, and RFID-based tracking to streamline operations.
Knoll now offers two packaging methods: carton packing and film wrapping. Packaged chairs are placed in corrugated containers with detailed information, while wrapped chairs are transported in their assembled form. To optimize trailer space, 80% of chairs are disassembled before transport. For wrapped chairs, a reusable transfer tray is used, making it easier to scan and track via RFID. Each tray is fitted with an RFID tag, and as chairs move through the system, the tags are updated with new order information.
At the end of each production line, chairs enter a guiding area where RFID stations help route them correctly. Operators use a console with a scanner, signal lights, and an RFID reader/writer to determine whether a chair should be packaged or wrapped. If it's packaged, it is placed into a box and sealed. If it's wrapped, it is transferred to a tray and the RFID tag is updated. A signal light indicates success or failure during this process.
Once chairs reach the shipping area, they pass through a strap-and-confirm zone, where barcode scanners and RFID readers verify the data. Depending on the type of packaging, chairs are either redirected back to the main line or sent directly to the loading dock. In the sorting area, another RFID reader verifies the tags, and the system directs chairs to the correct outbound lane or dock.
Carl Visscher, Knoll’s factory production manager, praised the system, noting that it has improved efficiency, reduced labor costs, and enhanced warehouse utilization. He also highlighted the reduction in forklift usage, which has lowered fuel and maintenance expenses while improving plant safety. With the new system, Knoll expects to achieve a strong return on investment within three years.
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