Case Study: Automotive Components Holdings, LLC achieves 6–9 fewer operators per day and improved production flexibility with Bastian Solutions

Automotive Components Holdings, LLC - Customer Case Study

Automotive Components Holdings, LLC (ACH Milan) needed to convey large, irregularly shaped plastic fuel tanks for the Ford F‑150 through a new production line while reducing material‑handling labor and adding a decoupling buffer; the line was running across three shifts, 5–7 days per week. ACH engaged Bastian Solutions to design and deliver a conveying and handling system to meet those objectives.

Bastian Solutions implemented a complete system — Allen‑Bradley controls (SLC 5/05 PLC and PanelView HMI), vertical lifts, pusher transfers, GescoFab belt‑over‑roller accumulation conveyors and an overhead belt conveyor — and supported testing through full production. Bastian Solutions’ solution delivered the required flexibility and buffering, cut staffing by about 2–3 fork truck drivers per shift (roughly 6–9 operators per day), and earned the vendor additional project work at the plant.

Automotive Components Holdings, LLC