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TriFactor Home / Material Handling Systems Case Studies / Tervis: Drinkware Manufacturer

Material Handling Case Study- 24VDC, WCS, Sortation

Company Description

Tervis, headquartered in North Venice, Florida, manufactures its distinctive insulated drinkware exclusively in America.  Since 1946, the crystal-clear, double-walled tumblers have kept cold drinks cold and hot drinks hot with their unique design and lifetime guarantee.  Tervis products are sold at tervis.com and more than 5,000 retail outlets nationwide.

Situation

Despite the economic complications most companies faced during the Great Recession, the insulated drinkware giant, Tervis, experienced unprecedented growth.  With their projected sales for the 2011 holiday season soaring even farther, the new system had to be in place by October.  Tervis required a solution that would improve manufacturing efficiency and order accuracy; reduce labor associated with shipping functions; provide increased packing speed due to less congestion and migrate to a new planned ERP System.

Assessment

To accommodate the growth in the number of tumblers produced and the growth in the number of outbound cases shipped, Tervis commissioned TriFactor Systems to conduct an engineering analysis of the shipping functions from each manufacturing cell to a consolidated shipping area.

This vital analysis provided a well-thought-out, jointly developed concept, budgetary estimates for capital planning and a detailed project schedule for implementation.  As a result, Tervis used this information to calculate the return on investment, which proved satisfactory, and resulted in Tervis contracting TriFactor to provide and install the material handling equipment and software systems. 

Material Handling Equipment, Tervis, TriFactor, 24VDC, WCS, Sortation

Solution

Material Handling System, Tervis, TriFactor, 24VDC, WCS, Sortation, Florida,Design Engineering

TriFactor engineers automated the current cell-based shipping functions with a central consolidated shipping area.  A central distribution point for packed orders was implemented to maximize the use of available cubic space available.    The TriFactor C3™ Warehouse Control System was customized to interact with the existing independent Navision/Microsoft Dynamics software.  Due to growth projections, the system needed to be modular system so that it can be modified and upgraded for the new oracle ERP solution planned for next year.  The plan boasts a lean facility using state-of-the-art equipment to increase throughput and decrease wasted labor and materials.  To keep this system in the top form, the Eye in the Sky advanced video technology was used.  This unique service allows Tervis the ability to provide TriFactor with secure remote access 24/7.  A wireless webcam at the Tervis location can be used to show TriFactor engineers the exact problem and location within the facility.  The real-time technology allows TriFactor engineers to view and troubleshoot not only PLC Controls and the WCS, but also live stream video of conveyor functionality.

Result

Material Handling System, Tervis, TriFactor, 24VDC, WCS, Sortation, Florida,Design Engineering

The project provided Tervis the manufacturing and distribution capacity needed for their current and future demand requirements.  TriFactor delivered the system on time.  Tervis was able to fulfill all of their orders throughout the 2011 holiday season without interruption. 

ROI

Less than 2 years.

System Summary

Company:
Tervis

TriFactor Provided:
Needs Analysis
Design Engineering
Mechanical, Electrical and Controls Installation
Operator and Maintenance Training

Size:
50,000 Square Feet

Facility Type:
Manufacturing / Distribution

Products Handled:
Quality Drinkware Manufacturer

Markets Served:
USA

Completion Date:
November 2011

Products Utilized:
Needs Analysis
24VDC Motor Driven Roller Conveyor
24VDC Motor Driven Roller Accumulating spirals
WCS - Cartonization and Packing Management; Parcel Shipping Management (Endicia, Fedex, & UPS)
Sortation
Automatic weigh in motion
Automatic print and apply shipping labels
Eye in the Sky live video for support & service