MODULAR MATERIAL HANDLING SOLUTIONS FOR LEAN MANUFACTURING

DESIGN & ASSEMBLY GUIDE

TABLE OF CONTENTS WHAT IS ECOFLEX? ........................................................................................................................................................2 THE SYSTEM ...................................................................................................................................................................2 WHY USE ECOFLEX? .......................................................................................................................................................3 HOW IS ECOFLEX SUPPLIED? .........................................................................................................................................4 DESIGN AND ASSEMBLY SERVICE ..................................................................................................................................4 ECOFLEX DESIGN GUIDE ................................................................................................................................................4 Terminology ...............................................................................................................................................................5 Component Application .............................................................................................................................................5 Dimensions ................................................................................................................................................................5 Roller Tracks Gradients ..............................................................................................................................................7 Ergonomics ................................................................................................................................................................7 ECOFLEX SAFE DESIGN ...................................................................................................................................................7 Joint Strength ............................................................................................................................................................7 Pipe Strength .............................................................................................................................................................8 Roller Track Strength .................................................................................................................................................8 Floor Loading .............................................................................................................................................................9 Stability ......................................................................................................................................................................9 Common Sense ..........................................................................................................................................................9 ECOFLEX DESIGN TIPS ..................................................................................................................................................10 Bracing .....................................................................................................................................................................10 Depth .......................................................................................................................................................................10 Dimensional Tolerance ............................................................................................................................................10 Width Constraints ....................................................................................................................................................11 ASSEMBLY GUIDELINES................................................................................................................................................11 Pipes ........................................................................................................................................................................11 Pipe & Joint Interfaces .............................................................................................................................................11 Joint Assembly .........................................................................................................................................................12 Inserts & End Caps ...................................................................................................................................................12 Adaptors, Accessories & Components .....................................................................................................................13 ASSEMBLY SEQUENCE GUIDE ......................................................................................................................................13 ABOUT INTEGRATED PRODUCTS & SERVICES ..............................................................................................................14 ECOFLEX APPLICATIONS ..............................................................................................................................................14

WHAT IS ECOFLEX? Ecoflex is a versatile modular component framework system, made up of steel pipes, rapid assembly steel joints and an extensive range of components and accessories. The system is designed to suit a wide variety of applications including manual handling, storage, assembly and manufacturing. Solutions are simple to design, assemble quickly and are completely reusable, suiting environments where Kaizen (continuous improvement) or Lean Manufacturing methods are employed. Assembled solutions can be quickly and easily modified, changed or rebuilt into something completely different. Only basic technical skills are required to achieve desired results; assemblies can be quickly constructed without the need for special tooling and require no welding or painting. There is little waste, as structures can easily be modified or rebuild. The pipe and joint components may be reused to build new solutions allowing continuous and cost-effective improvement to designs.

THE SYSTEM Pipes are steel tubing, nominally 28mm in outside diameter, ABS plastic-coated in various color finishes or stainless steel. Joints comprise of interlocking steel bracket components, clamped over the pipes and fastened in position with captive nuts & socket head bolts. Accessories including roller tracks, castors, hinges, latches and a wide range of other components fix also to the tubular framework in a simple snap or clip-on manner. Tools include a hacksaw to cut the pipes, a 5mm Allen key for rapid assembly of joints and a measuring tape to ensure solutions are cut and built to size.

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WHY USE ECOFLEX? 1. Simple: The Ecoflex coated pipe and joint system is universally recognized internationally and is easy to understand and learn. With no complex mathematics or structures involved, only simple loading specifications and ideas are required. Your employees will not need any special tools or advanced training. 2. Flexible: There is no material handling solution that is more flexible than the Ecoflex coated pipe and joint system. The system allows you to design, construct and adjust dimensions to your specific needs. The biggest advantage the Ecoflex coated pipe and joint system provides over others is that it can be quickly and easily modified or even reconfigured to suit changed in process, material or product. 3. Safety: The Ecoflex coated pipe and joint system was designed to be able to assemble and take apart quite easily. The pipes are ABS plastic coated and all joints are painted steel, and do not require and dangerous tools to put together. 4. Reduces Waste: The Ecoflex coated pipe and joint system can adapt to your material handling needs and streamline your production. By creating a system of marketplace racking, with line-side flow racking, the IPS coated pipe and joint system can work to eliminate unnecessary double handling and superfluous packaging, thereby reducing waste and promoting lean manufacturing. 5. Continuous Improvement: The Ecoflex coated pipe and joint system promotes a kaizen philosophy in your facility by allowing your personnel to get involved, be innovative and creative. Since the system is completely modifiable, it becomes the most efficient and effective way to promote continuous improvements in your facility. 6. JIT and Kanban: The customizability of the Ecoflex coated pipe and joint system allows for multi-purpose structures which can facilitate Just-In-Time production by implementing Kanban indicators directly into the racks. 7. Ergonomics: The customizability of the Ecoflex coated pipe and joint system allows equipment to be made to the exact specification of your operators. Unnecessary movements are eliminated by delivering material to the operator. Furthermore, the Ecoflex coated pipe and joint system is created with light components, making them easy to handle thus decreasing work-related injuries. 8. Environment: Since the Ecoflex coated pipe and joint system is completely modular, it can be re-used and recycled unlimited times to adapt to changes in your facility. The Ecoflex system also requires no welding or other environmentally adverse practices. Furthermore, since modular flow racking systems can be designed to return empty containers, it decreases the need for disposable packaging such as cardboard boxes.

HOW IS ECOFLEX SUPPLIED? Integrated Products & Services Inc. stocks and supplies the Ecoflex system, from its base in Newmarket, Ontario. Supply Options There are 3 main ways in which Ecoflex can be supplied (1) IPS designs and supplies assembled solution (2) IPS designs and supplies kit solution, customer assembles (3) IPS supplies stock, customer designs & assembles DESIGN AND ASSEMBLY SERVICE IPS Systems supports Ecoflex in North America with a Sales Team whose members include Kaizen and Lean Manufacturing experts with experience using the Ecoflex system in the Automotive Manufacturing Industry, plus a team of qualified CAD Engineers and an expert assembly team. Design Sales representatives visit your site to discuss, consult and advise, before offering an Ecoflex solution for almost any material handling application. Sketches are developed into technical drawings, using the latest CAD and design software. Following an order for an IPS designed solution, customers receive a detailed specification prior to manufacture and delivery including fully scaled and dimensioned drawings plus an optional 360° 3D view. Assembly Customers can choose to have their solutions delivered fully assembled. So, following drawing approval, IPS will build the solution in-house and deliver to customer, ready for use. Some larger solutions are delivered to site partially assembled, and then finally completed by the IPS installation team. ECOFLEX DESIGN GUIDE To ensure an Ecoflex solution is successful it is advisable that sensible planning is implemented before any building or assembly commences. The most important stage of planning is the design phase as this takes into consideration both the application and function of the solution and any safety implications. But, before design begins, some basics must be understood, such as the component names, their respective functions and dimensions.

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Terminology It is quick to become familiar with terminology: ‘E’ parts are joined together to form a number of standard assembled ‘ES’ joints, for example an ES-1 is made from 2x E-1’s.

And some versatile parts e.g. E-2 being used as part of all assemblies ES-2, ES-3, ES-5, but this means the assembled number doesn’t always correspond to the part number; for example ES-3 is made of 2x E-2’s and 1x E-4.

‘GP’ adaptors are associated with track and ‘GS’ adaptors with pipe.

Component Application Planning ahead will ensure a successful solution is produced with minimal effort and waste. Ecoflex has the capabilities of including design factors such as ease of adjustability that can be built in using Design for Assembly techniques, or the ability to add to the design post build for continuous improvement. These factors may be a simple case of asking which orientation the joint should be used in to gain the maximum benefit. For example a three-way pipe assembly may be achieved using the GA-2 joint assembly in different orientations to give different application benefits. Dimensions Pipes are nominally 28mm in outer diameter, joints 28mm in inner and 33mm in outer diameter.

Ecoflex solutions are dimensioned pipe centre to pipe centre, as if wireframe assemblies.

Most pipe lengths are terminated within a joint ‘sleeve’, and so their lengths are calculated as joint centers minus 70mm (2x35mm).

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Roller Tracks Gradients Typically roller track is installed at 6% gradient. This gives an optimum gravity roll speed for boxes in most cases.

Depending on the roller track pitch, the depth of the racking is determined by the full wheel pitch increment cut of the track i.e. every 36mm for the RT-40A track. Ergonomics The ergonomics of the system need careful planning to ensure safe use and efficient operation are achieved. Working heights, picking heights, bending & reaching limits etc. for the most part are the responsibility of the company using Ecoflex; some cover this in their own Health and Safety policies. ECOFLEX SAFE DESIGN What is the safe working load (SWL) of the Ecoflex system? Is the system safe for the application it is designed for? How can I calculate the SWL for my design? Remember to always work well inside the guidance figures of loads which follow, to allow a safety margin. Safe design ensures that the system does not fail causing damage to equipment or stock and avoids injury or accident. Safe design includes considerations for the following: • • • • • •

Joint strength Pipe strength Track strength Floor loading Stability Common sense & experience

All the points above need to be considered before deciding a system is safe for use. For example, a rack may not overload any of the pipes or joints, but the castors may be under specification and so not suited to the intended load. Once each of the failure modes is considered and the applied loads are considered safe, then the system is considered to be fit for use. Joint Strength Each assembled joint has a maximum load capacity of 80kg in shear before slippage. This is based on an approximate bolt torque of 10Nm (7.4 ft-lb) for each of the fixings in a joint assembly. This applies to pipes being pulled out of a joint (X direction) and through a joint (Y direction)

Pipe Strength Pipes make up the framework of the Ecoflex system, connected together by joints. Pipes will flex and bend under an applied load and, up to a certain point this is acceptable and the pipes will not permanently deform, returning to their original state when the load is removed.

However, beyond a certain load, the bending of the pipe will be permanent and even lead to failure. This load varies with the length of the pipe under load, decreasing as the unsupported span of a pipe increases. Typically horizontal pipes, with a central point load are considered to be the worst load case and vertical pipes considered the best load case under gravity applied loading. Roller Track Strength Similar to pipe loading, roller tracks will flex and bend under load. However, loads are almost always applied to a horizontal roller track, with a slight gradient of about 6%. Two considerations for the roller track are the failure load for the roller track profile and the failure load for an individual wheel.

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Floor Loading Loads in an Ecoflex system are transferred to the floor, either through the pipes, feet or castors. In all cases, ensure the floor is capable of supporting the loads. • • •

Pipe safe floor loading is achieved providing the pipe in contact with the floor is not subjected to loads that exceed the recommended safe weight limits. Feet generally have threaded steel stems, which fix into threaded steel inserts fitted into the end of a vertical pipe. Castors are load rated, which varies with wheel size, castor type and specification. For a four-castor arrangement, maximum loads must be calculated on three of the castors and for six-castor arrangement on four of the castors.

Stability To ensure an Ecoflex assembly is stable, the height to width ratio of static units should not exceed 5:1 unless permanently floor fixed. Units with castors should maintain a lower ratio, since if they hit an obstruction on the floor, they can more easily topple. The table below illustrates a 5:1 ratio. The arrangement of the castors or feet determines the effective base dimensions, so this is crucial for determining the maximum safe structure height. Each application needs individual consideration. In the table below, for example, it can be seen that insert castors provide the greatest stability as they have the greatest base width. Also, simply repositioning the plated castors moves the point of floor contact, changing the base width and in turn affecting the safe working height.

1) Insert Castors 2) Plated Casters (Crossways Mounted) 3) Plated Casters (Lengthways Mounted)

Rack Width (C-C in mm)

Castor Size (mm)

Base Width (mm)

Height to Base Ratio

Max Height (mm)

500 500 500

125 125 125

380 165 290

5:1 5:1 5:1

1900 825 1450

Common Sense When designing an Ecoflex solution, common sense safety considerations must also be a factor of the design process. For example, consider where the center of gravity will be on both a fully loaded and partially loaded rack. Also, as a rule of thumb, if an Ecoflex solution is to be loaded and picked by hand, then generally it is the right system. If loading and unloading requires mechanical assistance, then perhaps an alternative solution should be explored.

ECOFLEX DESIGN TIPS Despite each application being customized in terms of size, design and loading, there are a few basic structural procedures that should be adhered to for safety and stability. Note the images have been over-exaggerated for explanation purposes and these issues only occur for much larger structures than drawn here. Bracing Add diagonal bracing for durability and to reduce the risk of the application moving out of square, thus reducing the risk of the joints coming apart. Similarly, where parallel pipes run for fitting plated castors, add perpendicular cross ties (using ES-7).

Depth Depending on the load, pipe and track should not in most cases exceed 1500mm span without the addition of further supports (refer to load tables).

Plan square-ness (i.e. a square “footprint” should always be designed-in by using ES-2 joints at the 4 corners of the rack base, or by suitable diagonal ties in the base of the rack as a minimum to keep it square. Mobile units may require additional bracing to retain rigidity if moved when loaded. Dimensional Tolerance Ecoflex is designed with +/-1mm tolerance. This ensures that pipe lengths are fully inserted into joints, which maximizes the effectiveness of the clamping friction. Similarly, rack depths for roller tracks are set around a full pitch length of the roller track, to ensure roller tracks sit fully in the adapter brackets.

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Width Constraints According to anticipated loads the maximum width of a rack should generally not exceed 1500mm before adding additional uprights to reduce the deflection. Alternatively individual modules can be built and joined together. 1500mm is a guide only, since load applications will vary. Cross-pipes taking excessive loading (see recommended safe weight limits chart) can be strengthened by using double pipes, advisable for racks over 1500mm wide.

ASSEMBLY GUIDELINES Assembly of an Ecoflex solution can be done from either a pre-designed solution, where the pipe lengths, joint and component quantities are fully specified from a drawing materials list and the outcome is known prior to assembly; or by developing the design as the solution is being built, adjusting and modifying until the desired solution is reached. Either way, certain assembly guidelines need to be adhered to. Pipes Pipes are very basic and therefore simple to prepare. Cut the pipes to length, with hacksaw, chop saw or band saw and de-burr cut ends; a sharp cutting blade will minimize burring. Pipe & Joint Interfaces It is important that pipes are correctly inserted into the joints. This ensures that pipes are being correctly clamped and maximizes the stability and safety of the system. Ensure the pipes are fully inserted into the joint before tightening. For joints in which a pipe terminates, there should be 30mm of joint sleeving the pipe.

Do not splice, or join two pipe ends inside a joint head. This is not considered a safe practice.

Joint Assembly Position the joint components in place over a pipe. Insert the T-nut(s) into the recess(es) on the least accessible side of the joint assembly, with the shoulder of the nut sticking through the hole and the flat edges captivated by the recess sides. The bolt may then be inserted into the joint assembly from a more accessible side of the joint, typically on the outside of the rack, there the bolt head may be tightened by hand at first, then by 5mm Allen key or power tool with suitable adapter.

The shoulder of the nut will improve the interface between the nut and bolt, allowing the threads to engage inside of the joint assembly. Note, most joints need to ’dovetail’ over the pipe, before being fixed together. Ensure they interlock and clamp the pipe correctly. An approximate torque of 10Nm (7.4 ft-lb) is recommended for optimum clamping strength; too much under this torque and the joints may slip; too much over this torque and the joint components may deform under the excessive clamping force. Joints can be removed and re-assembled. Optional self-locking nuts and bolts are available for a more permanent solution. Inserts & End Caps Threaded inserts and inner end caps are push fit and hammered into the open pipe ends.

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Adaptors, Accessories & Components All other components are quick and easy to use; their application implicit, so they require little or no training for assembly and use.

ASSEMBLY SEQUENCE GUIDE This section follows the suggested assembly route for an example of a FIFO - 4 level feed / 1 return flowrack showing examples of different variations at each stage on the left hand side: 1: Build side frames with feet

2: Add structural bracing

3: Add cross-pipes

4: Fix casters

5: Fit track and guide at set height

6: Fit remaining levels

• • •

Track slots into track adaptors that is then a push fit onto the cross pipe. Guide simply slides onto the track before attaching track adaptors. Track generally supported underneath with at least 1x cross pipe.



Set levels at required pitch with track at 6% nom. gradient

7: Add & secure accessories

• • •

Attach worktops/ panels/Tool rails etc. Add inner caps Check dimensions against drawing, ensure joints fully inserted and appropriate joints are perpendicular

ABOUT INTEGRATED PRODUCTS & SERVICES Integrated Products & Services Inc. was established in 2006 as a lean manufacturing material handling consultation firm and have grown into a leader in the distribution of modular pipe racking and shelving systems in Canada. As well as providing unit based bulk sales of Ecoflex pipes, rollers and components, we have separated ourselves from the competition by offering our unique design, and implementation services. ECOFLEX APPLICATIONS FIFO / Flow racks / Gravity Feed Line side Order Picking Assembly Lines Work Benches Work Stations Multi-Function Work Station Trolleys / Carts Tool Trolleys Mobile Storage Storage Shelving Pigeon Hole Dunnage Bags Display Stands / Notice Boards Tables Part Stands Custom Solutions

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Mailing Address: 16715 Yonge St. Suite 900 Newmarket, ON L3X 1X4 Canada Toll Free: 1-888-207-0655 Tel: 1-905-918-0635 Fax: 1-905-918-2869 Web: www.ipscoatedpipes.com