Project Goals

• Improve operator ergonomics and safety

• Increase manufacturing throughput

• Reduce part entanglement and jams

• Improve loading and unloading efficiency

Key Constraints

• Fit beneath existing blanking press output

• Support forklift and pallet jack handling

• Stack safely while fully loaded

• Deliver parts reliably without operator intervention

• Use simple relay-based controls (no PLC)

• Include safety interlocks and operator safeguards

• Provide maintainable, fabrication-ready systems with documented replacement components

Engineering Approach

• Developed and evaluated multiple feeder and Gaylord concepts

• Iterated layouts around evolving operational constraints

• Refined geometry for manufacturability, reliability, and serviceability

• Integrated control, guarding, and operator safety considerations into system layouts

• Managed revision tracking, quoting, and cost optimization throughout development

Result

• Functional material handling concepts developed and evaluated

• Improved operator accessibility and manufacturing flow

• Reduced dependence on manual part organization

• Established a scalable foundation for future production refinement