case study - Toyota Manufacturing UK

Toyota Manufacturing UK has placed a further order with Welconstruct for its Carton Live Storage system, this time for the manufacturer’s Avensis and Corolla assembly lines. To date, Welconstruct has installed more than 300 bays of carton live storage at the Burnaston, Derbyshire plant.

The latest order was designed, supplied and installed within a month in line with Toyota's requirements following its £50 million investment programme to meet the increased market demands on its products. As part of the ongoing programme, Toyota has replaced the existing racking with Welconstruct's live storage to improve space utilisation. Welconstruct's Carton Live storage system allows Toyota to manage a First In, First Out stock rotation, in line with its Just In Time production system.

The concept of First In, First Out stock rotation is ideally satisfied by the Live Storage method of handling and storage. It utilises live storage beds which are installed within pallet racking frames supported by a universal bracket. Each storage lane ideally contains one product line which is placed on the conveyor and travels by gravity to the picking face and main assembly line.

Ian Warby, Welconstruct's automotive sector manager comments, "The design of the Live Storage method gives a greater weight capacity and ability to store deeper than other conventional live storage systems".

He continues "In addition its flexibility us such that Toyota can vary the configeration to suit its usage - for example by changing the type and number of wheels or rollers, or the pitch and load capacity in each lane".