Peterbilt - ASRS Aisle 4 Retrofit Project

Project Overview

Peterbilt faced growing demand for their larger integral cab sleeper products, which required increased production volumes and corresponding expansion of automatic storage and retrieval capacity for these units. The company sought a solution that would enhance their existing ASRS capabilities without disrupting ongoing production operations or expanding the overall footprint of the storage system.

The project focused on retrofitting the existing ASRS Aisle 4, building upon the original Daifuku ASRS system installed in 2016 that had demonstrated reliable performance with minimal downtime incidents. A key priority for Peterbilt was shortening the project timeline, while ensuring that production operations remained uninterrupted throughout the modification and installation process.

Daifuku was selected to engineer and implement the solution, leveraging their expertise with the existing system to deliver a targeted retrofit that addressed the specific storage capacity needs for the large cab sleeper units.

Technical Solution

ASRS Aisle 4 Retrofit Engineering

Daifuku engineered comprehensive modifications to ASRS Aisle 4, tailored to accommodate the larger integral cab sleeper units. The retrofit focused on optimizing the storage configuration within the existing aisle footprint, eliminating the need for facility expansion. The engineering work included adjustments to the ASRS structure, storage positions, and retrieval mechanisms to handle the specific dimensions and requirements of the larger products.

Key Features

The retrofit of ASRS Aisle 4 directly increased storage capacity for Peterbilt's large integral cab sleeper units, addressing the core business need driven by increased product demand. The solution maximized the utility of existing space without requiring facility expansion, delivering a cost-effective alternative to new construction.

A standout feature of the project was the achievement of zero production disruptions throughout the modification process. Daifuku's engineered installation plan ensured that Peterbilt's manufacturing operations continued uninterrupted while the ASRS upgrades were implemented.

The creative crane deployment solution for high-elevation access demonstrated innovative problem-solving, allowing modifications to the 30ft-high rollup door without compromising safety or operational continuity. This approach eliminated the need for more disruptive access methods that could have impacted production.

The project's completion 6 weeks ahead of schedule, including full software commissioning, exceeded Peterbilt's timeline requirements. This early delivery provided additional operational flexibility and accelerated the realization of increased storage capacity benefits.

The retrofit built upon the reliability of the original 2016 Daifuku ASRS system, which had a proven track record of minimal downtime. By leveraging existing infrastructure, Peterbilt avoided the costs and risks associated with implementing an entirely new storage system.

Results & Benefits

The primary outcome of the project was a significant increase in automatic storage and retrieval capacity specifically for Peterbilt's large integral cab sleeper units, directly supporting the company's ability to meet growing product demand. This capacity expansion enabled increased production volumes without storage bottlenecks.

The project was completed 6 weeks ahead of schedule, including full software commissioning, exceeding Peterbilt's timeline expectations. This early completion allowed the company to start utilizing the expanded storage capacity sooner than planned, accelerating return on investment.

Critical to the project's success was the achievement of zero disruptions to Peterbilt's production operations throughout the entire retrofit process. This uninterrupted operation ensured that production targets were maintained, avoiding costly downtime and order delays.

By retrofitting the existing ASRS Aisle 4 instead of expanding the facility footprint, Peterbilt achieved storage capacity growth in a cost-effective manner. This approach minimized capital expenditure on building expansion while maximizing the utility of existing infrastructure.

The project maintained the reliability track record of the original 2016 Daifuku ASRS system, with the retrofitted aisle integrating seamlessly into the existing setup. The continued minimal downtime ensures ongoing operational efficiency and productivity.

Challenges & Solutions

The project faced three primary challenges, each addressed through targeted solutions developed by Daifuku and Peterbilt's project team. The first challenge was accessing the rollup door located 30ft above ground level, which was necessary for completing the ASRS modifications. The solution involved using a large external construction crane to carefully place a smaller crane inside the building, providing safe and efficient access to the high-elevation area without disrupting operations or damaging facilities.

Second, Peterbilt requested that all possible avenues be explored to shorten the project timeline. The project team responded by implementing process efficiencies, optimizing work sequences, and maintaining close coordination between all stakeholders. This proactive approach resulted in the project being completed 6 weeks ahead of schedule, including full software commissioning.

Third, the need to perform significant modifications to an active ASRS aisle while keeping production operations uninterrupted presented a major logistical challenge. Daifuku engineered a phased installation plan that scheduled critical work during non-peak periods and maintained system functionality for other product lines throughout the retrofit. This careful planning and execution ensured that Peterbilt's production targets remained on track throughout the project.

System Integrator

Daifuku served as the system integrator for the ASRS retrofit project, bringing extensive expertise with their original 2016 ASRS installation at Peterbilt. The company was responsible for engineering the modifications to ASRS Aisle 4, developing the production-friendly installation plan, implementing the high-elevation access solution, and completing the software commissioning.

Daifuku's deep understanding of Peterbilt's existing system and operational requirements was instrumental in delivering a solution that met all performance criteria while avoiding production disruptions. Their ability to address unique challenges—such as the high-elevation door access—and deliver the project 6 weeks early demonstrated their commitment to customer satisfaction.

Peterbilt expressed satisfaction with Daifuku's performance, noting the positive experience working with their team and the reliable performance of the original 2016 system. The successful completion of this retrofit project has strengthened the partnership between the two companies, with Peterbilt looking forward to continued use of Daifuku's equipment and services.