align production systems: innovation in movement

Align Production SystemsOverview

Who We Are• Align is a designer, manufacturer and

integrator of material handling and manufacturing automation systems

• Our emphasis: to help our clients overcome production obstacles and maximize productivity by leveraging the latest movement and positioning technologies

History

• 50 years of heavy load movement experience under the Airfloat banner

• Spun off turntable and lift businesses in 2013• Became exclusive North American partner of

Silvestrini the same year• Now go to market under the parent company

name Align Production Systems

Parent Company and Brands

AIR BEARING EQUIPMENT

Airfloat

Who We Are

• Primarily known as a manufacturer of air-film equipment• Innovator of the air bearing (or “air caster”)• Enable other heavy manufacturers to better automate their

manufacturing process• 50 years of experience

What is an Air Bearing?• Pneumatic device

similar to a hovercraft

• Compressed air passes through a flexible polyurethane diaphragm

• Forms a thin air film beneath load

• Enables nearly frictionless, omnidirectional movement

• Made of chemical- and wear-resistant material

Typical Air Skid Setup

• Typically deployed in circuits of three or four (like wheels)

• Used in rigging applications and semi-annual maintenance moves

• Kits available in wide range of sizes and capacities

• Include a multi-port controller and air hoses

Kentucky Trailer – Louisville, Ky.Workers move 50-ft.-long, 20,000-lb. trailers by hand, in any direction. This allows the trailers to fit in spaces too tight for fork trucks to safely maneuver.

GE Transportation – Erie, Penn.75-ft.-long, 300,000-lb. diesel locomotives float on specially designed air transporters. The equipment helped boost output from 17 to 22 locomotives per month – a 29% gain.

Progress Rail – Muncie, Indiana100-ft.-long, 500,000-lb. diesel locomotives float on specially designed air bearing shuttle. The equipment allowed the customer to have four times the throughput in the painting of locomotives.

• Progress Rail

• CNH

• Bombardier

• Caterpillar

• … and More

More Recent Projects

Primary BenefitsOutstanding ROI

Low capital investmentIncrease productivityLower energy costs

Supports Lean ManufacturingEasily reconfigure assembly lines

No in-ground installationMinimize wasted movement (e.g.,

attaching lifting straps, etc.)

Primary Benefits (cont.)Safety

Improve ergonomicsReduce worker strain and injuryReduce dependence on forklifts

MaintenanceLower maintenance costs – few

moving parts to breakReduce floor and wall damage

Better housekeeping habits

Air Bearing Myths• “It’s really loud…”• “It creates a lot of

dust…”• “It requires

tremendous air pressure…”

• “It won’t work on our floor…”

• “It’s difficult to control…”

All Incorrect!

Air Bearing Requirements

• Floor – flat, level, smooth and non-porous

• Most power-troweled concrete floors are OK

• Easy, low-cost floor improvements are available

• Air – most plant air systems are suitable

• Need sufficient airflow volume and pressure

• Air consumption is proportional to air bearing perimeter

Axial Industrial Turntables

Some Axial Turntables:Multi-Positional Fitted with Air-bearings

Fitted with Slewing bearingsCustom

Air Bearing TurntablesAvailable in many different sizes and capacities, with or without drive motors. Often used for container handling in factory settings. May include integrated lift/tilt tables or other attachments.

Air Bearing Turntables

John Deere Photo Lab Turntable

Pit-mounted Air Bearing Turntable

Ford Motor Company – Woodblock flush floor air bearing 28’ turntable with four independent inset turntables. Designed to handle 80,000 lb load. Electric edge drive with back up drive.

Pit-mounted Air Bearing Turntable

General Motors – Six- position rack indexing turntable, with remote operator control stand feeding to controls box with PLC for plant interface.

Floor-mounted Air Bearing Turntable

Robotic Turntables – Heavy duty glass rack turntable designed for robotic interface. Electric Edge Drive.

Robotic Cell Air Bearing Turntable

Mechanical Slewing Bearing Turntables

Available in many different sizes and capacities, with or without drive motors.

Available in many different sizes and capacities, with or without drive motors.

Mechanical Wheeled Turntables

INDUSTRIAL LIFTING & POSITIONING SOLUTIONS

Scissor Lift Tables

• Pneumatic & Hydraulic Scissor Lifts

• Capacities from 2,000 lbs. to 10,000 lbs.

• Modular design for easy addition of container tilts or turntables

• Available in double and triple scissor lift models for maximum raised height

• Electric trip bar, internal power packs, casters and other options available

Specialty Scissor Lifts

‘Super Series’ Hydraulic Lifts• Capacities from 10,000 lbs.

to 25,000 lbs.• Built for extreme lifting

applications

Loading Dock Lifts• Safer and less expensive

than concrete ramps• Work with variety of trucks

and trailers

Additional Safebilt Products

Container Tilts• Capacities from 2,000 lbs.

to 6,000 lbs.• 30⁰ and 45⁰ tilt models• Bolt-on or standalone

operation

Pneumatic Pallet Jack• 7,500 lb. capacity• Spark-free operation• Ideal for explosive or

hazardous environments

INDUSTRIAL POSITIONERS

Silvestrini N.A.

• Heavy duty welding positioners

• Headstock & tailstock positioners

• Two- and three-axis industrial manipulators

• Pipe/vessel turning rollers

Silvestrini N.A.• Founded in Bologna, Italy• 100-year history, fourth-generation owned• Maker of hydraulic positioners, manipulators,

and turntables for welding and assembly• Has historically gravitated toward heavy,

difficult positioning challenges• Now available in North America in partnership

with Align Production Systems

Silvestrini Equipment

Pipe-Turning Rollers Three-Axis Orbital Positioners

Two-Axis Welding Positioners Three-Axis Welding Positioners

Two-Axis Welding Positioners

• Capacities from 400 lbs. to 40 tons• Offer tilting and variable-speed

rotation• Manual, motor-driven and hydraulic

tilt models available• Positioner need not be anchored to

the floor• Heavy-duty SA models are virtually

maintenance-free and last 30 years or more under normal conditions

• Reduce cycle time by 45-50% over static positioning

Three-Axis Welding Positioners• Capacities from 1,000 lbs. to 40 tons• Offer tilting, variable-speed rotation

and hydraulic lifting• Robust 5-to-1 Factor of Safety (FoS)• Machine feet are located behind the

table so that large pieces rotate freely, even when table is in vertical position (90° tilt)

• Heavy-duty AVSA models are virtually maintenance-free and last 30 years or more under normal conditions

• Reduce cycle time by 55-60% for larger work pieces

Headstock & Tailstock Positioners

• Offer hydraulic lifting and electric gear-motor rotation

• Capacities from 1,000 kg. to 40 tons

• 5 to 1 Factor of Safety (FoS)• Hydraulic safety cutoff• Slide positioning for varying

fixture lengths• Optional work-holding jigs

and fixtures

Three-Axis Orbital Positioners

• Offer rotation, lifting and tilting

• Capacities from 1,000 kg. to 40 tons

• 5 to 1 Factor of Safety (FoS)• Advanced motion control

for smooth rotation• Hydraulic safety cutoff• Optional clamping system

(chuck)

Pipe-Turning Roller Positioners

• Capacities from 1,000 kg. to 90 tons

• Includes motorized driver section and idle section

• Rotate pipes/tanks up to 8 meters in diameter and 80 meters long

• Powered by two three-phase 380V 50Hz motors

Our Capabilities

Concept Engineering Fabrication Assembly Service

Next: Industries Served

More about Align

•Headquartered in Decatur, IL since 1964•Sales offices in Detroit and St. Louis•Design & manufacture everything we sell•Projects completed with 90% of Fortune 500•60,000 sq. ft. of manufacturing space•3,000 sq. ft. ‘Innovation Center’ for engineering•Laser-cutter reduction used on all designs•Service and/or refurbish what we sell

Industries Served• Aerospace• Agriculture• Appliance• Automotive• Chemical• Construction• Locomotive• Mining

• Nuclear• Prefabricated Home• Printing• Rigging• Ship Building• Steel• Theater and Stadium

Seating

Next: Our Clients

… and Many More

Our Clients Include:

Next: Air Bearing Myths

European Clients• Fiat• CNH• Caterpillar• Hitachi• Komatsu• General Electric

• Bell/Agusta (BAAC)• Alcoa• Daewoo• Peugeot• ABB• Citroen

Silvestrini equipment is found in over 20 countries

Recent Awards & Achievements

• 2000 – Awarded Q1 Preferred Quality Award by Ford Motor Co.

• 2008 – Partnered with GE Transportation to create world’s first moving assembly line for locomotives (Erie, Penn.)

• 2009 – Awarded Performance Excellence Award (Gold Level) by Boeing for excellent supplier performance

• 2012 – Awarded Recognition in Innovation by Steel Manufacturers Association (SMA)

Next: Final Questions

Thank YouQuestions?