Case Study: Automated Overhead Storage of 600 Filters

In many industries, the main constraint is not production capacity but available space and the smooth flow of products.

This was the challenge faced by a manufacturer specializing in filtration fabrics, which recently turned to OCA’s teams for expertise.

Before our intervention, the filtration fabrics produced by our client (each with a surface area of up to 15 m²) were dried and stored on floor-level racks.

This setup led to several major issues:

•    significant clutter in the workshop

•    difficulty for operators to move around

•    heavy and repetitive handling

•    suboptimal production flow

Furthermore, managing movement and intermediate storage were clear obstacles to our client’s productivity.

Coated fabrics present a significant technical constraint: they must never come into contact with one another.

This required the creation of a material handling solution capable of ensuring:

•    no contact between parts

•    secure overhead storage

•    smooth and continuous flow

•    a gradual reduction in the spacing between the fabrics as they dry

To best meet our client’s specifications, the OCA teams designed and installed a custom overhead material handling system that enables:

•    automatic and ergonomic loading of the canvases

•    automated transfer of the canvases to the drying area

•    overhead storage of more than 600 canvases

•    a continuous production flow

In addition to the benefits mentioned above, this solution minimizes floor space requirements by utilizing the overhead space in the production workshop, which had not been used until now.

The implementation of the overhead handling system brought immediate benefits to our client:

• increased production space without the need for expansion
• improved working conditions and reduced risk of musculoskeletal disorders for operators
• consistent production rates
• overall optimization of production flows

This project highlights a common reality in industrial settings: performance losses are often linked to poorly optimized product flow and insufficient use of production space.

For over 45 years, OCA—Ouest Convoyeur Automatisme—has been supporting manufacturers in designing custom material handling solutions by developing overhead and floor-level conveyors as well as specialized machinery.

These solutions can incorporate dynamic storage and automation to ensure improved flow and traceability of production streams.

Our teams will assist you in analyzing and designing solutions tailored to your industrial needs.