Knoll Mfg., a leading office furniture manufacturer based in East Greenville, Pennsylvania, is well-known for its innovative and timeless designs. The company has built a strong reputation for producing "exciting, mature, and long-lasting" office furniture. Their dedication to modern design and technological advancement has led to significant improvements across various product categories, including office systems, chairs, archives, storage solutions, workbenches, desks, wooden boxes, textiles, and accessories.
Recently, Knoll introduced an advanced material handling and order tracking system specifically for its office chair product line. This system has dramatically reduced cutting costs, eliminated order processing errors, and accelerated the shipping process. By integrating RFID technology, barcode scanning, and equipment from Stokes Material Handling, Accu-Sort Systems, and BP Controls, the company has created a more efficient and accurate workflow.
The production facility in East Greenville houses four office chair lines that manufacture popular brands such as Chadwick, Life, RPM®, and Bulldog®. To ensure accurate tracking, each assembled chair is wrapped in plastic film and placed on a reusable tray equipped with an RFID tag. These tags are encoded using an RFID writer/reader, allowing the system to identify and track each unit throughout the factory.
Previously, the process was manual and error-prone. After assembly, chairs were labeled with detailed information, then wrapped or packed into boxes and transported via forklifts to distant storage areas. This method caused several issues, including forklift maintenance, fuel costs, and safety concerns, as well as the risk of misrouting orders.
To address these challenges, Knoll partnered with Stokes Material Handling to develop an automated system capable of identifying chairs by order number, destination, and type, automatically sorting them, and directing them to the correct loading gate. This system includes advanced conveyor belts, automated lifts, and RFID-enabled tracking, making the entire process faster and more reliable.
Knoll also optimized its packaging methods, offering both carton and film-wrapped options. For carton-packed chairs, detailed labels are printed and scanned automatically. Wrapped chairs, however, required a different approach, prompting the use of RFID-equipped transfer trays for better tracking.
At the end of each production line, a guiding area uses RFID technology to determine whether a chair should be packaged or wrapped. Staff can manually guide the process using a console equipped with a scanner, reader/writer, and signal lights. If the RFID tag is successfully written, the chair moves forward; otherwise, it is flagged for correction.
Once the chairs reach the shipping area, they pass through a scanning station where either a barcode or RFID tag determines the next step. Whether it's strapping, bundling, or direct shipping, the system ensures accuracy and efficiency.
The implementation of this integrated RFID and barcode system has significantly improved Knoll’s operations. It has enhanced productivity, reduced labor costs, and minimized shipping errors. According to Carl Visscher, the factory production manager, the new system has also cut forklift usage, lowering fuel and maintenance expenses while improving overall plant safety.
Knoll expects to see a strong return on investment within three years, considering all associated costs. With this system in place, the company is now better positioned to meet growing demand while maintaining high standards of quality and efficiency.
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