Gravity Flow Conveyor Case Study DMS

Customer: Detroit Manufacturing Systems

Location: Detroit, MI

Application: General Storage

Product:  Lewco Gravity Conveyor

Company Overview:

• Detroit Manufacturing Systems (DMS) is a Detroit-based automotive manufacturer specializing in complex interior and modular assembly solutions for major automotive OEMs. Operating large-scale production facilities in the Metro Detroit area, DMS focuses on quality manufacturing, operational efficiency, and workplace safety while supporting high-volume automotive production programs.

Detroit Manufacturing Systems needed to improve the way assembly totes were delivered into and removed from an active production work cell. The existing process relied heavily on fork truck traffic and manual tote handling, creating several safety, ergonomic, and workflow concerns within the production environment.

Operators inside the work cell were routinely working near fork trucks during material replenishment cycles. Full totes were either delivered directly by lift truck or manually slid into the operator area, increasing the risk of accidental contact between equipment, material, and employees. In a fast-paced manufacturing environment, this created unnecessary exposure to potential injuries and workflow disruptions.

In addition to the safety concerns, the process also created inefficiencies during normal production activity. Fork truck movement near the work cell introduced congestion around operators and interrupted the natural flow of assembly operations. Material handlers needed a more controlled and repeatable process that would allow totes to move safely into position without requiring direct equipment interaction inside the cell.

Ergonomics were another major concern. Operators frequently needed to reach, reposition, or manually maneuver totes during assembly tasks, increasing physical strain throughout the shift. The customer wanted to create a more ergonomic workstation layout that would improve accessibility to assembly components while reducing unnecessary movement and handling.

The empty tote retrieval process also lacked organization. Removing empty containers from the cell required additional traffic and movement near operators, contributing to congestion and reducing overall workflow efficiency.

To address the operational, safety, and ergonomic concerns within the production work cell, The Safety Source designed and supplied a fully customized gravity-assisted material handling solution for Detroit Manufacturing Systems.

Rather than relying on fork trucks to directly deliver and retrieve totes inside the operator area, the new system created a controlled material flow process that allowed full totes to safely move into the cell while simultaneously providing a dedicated path for empty tote removal.

The complete solution consisted of:

• -A custom inbound gravity flow conveyor
• -A custom outbound gravity flow conveyor
• -A low-profile ball transfer table assembly
• -Heavy-duty adjustable support systems
• -Integrated safety and alignment features

Each component was specifically engineered around the customer’s workflow, operator accessibility requirements, and space limitations within the production environment.

The inbound gravity conveyor was designed to safely guide full totes into the operator area using controlled gravity-assisted movement. To improve tote alignment and prevent shifting during transfer, the conveyor incorporated 48-inch funnel guides on both sides of the system. These guides helped ensure totes consistently moved into the correct position while minimizing the risk of sudden movement near operators.

The conveyor was also designed with low-set rollers and a gradual elevation decline to create a smooth and ergonomic tote transfer point inside the work cell. Because the production environment required low operating elevations, the system was engineered so one end of the conveyor could sit as close to the floor as possible while still maintaining proper support and structural integrity.

Following installation of the custom gravity conveyor and ball transfer system, Detroit Manufacturing Systems experienced immediate improvements in workplace safety, material flow organization, and operator ergonomics within the production work cell.

One of the most significant improvements was the reduction of fork truck interaction near operators. By creating a controlled gravity-assisted tote delivery and retrieval process, the system helped minimize the need for lift trucks to enter or approach the active work area during normal production replenishment. This created a safer environment for operators while also reducing congestion and interruptions within the cell.

The new system also improved the consistency and predictability of material movement throughout the production process. Full totes could now be safely staged outside the work cell and guided into position through the conveyor system, while empty totes followed a dedicated outbound path for retrieval. This created a cleaner and more organized workflow that reduced unnecessary movement and improved overall operational efficiency.

Key Results

• -Reduced fork truck traffic within the production work cell
• -Improved operator safety during material replenishment
• -Safer and more controlled tote delivery process
• -Organized and efficient empty tote retrieval
• -Improved ergonomic access to assembly components
• -Reduced operator strain and unnecessary movement
• -Improved workflow consistency and material organization
• -Reduced congestion and disruption around the work area
• -Durable system designed for continuous industrial use

By implementing a custom gravity-assisted material handling solution, DMS was able to improve both workplace safety and operational efficiency while maintaining a simple, reliable, and highly effective production support system.