Case Study
Flynn Canada Case Study
Project Overview: Custom-designed equipment to streamline the assembly of large and heavy wall products.
Challenge
Flynn Canada approached Kear Fabrication with a unique challenge: they required a solution to assist with the assembly of their large and heavy wall products. Initially, their request was for a table that could facilitate assembly on both sides. The table needed to be durable, versatile, and integrate seamlessly into their existing production workflow.
Solution
Kear Fabrication proposed a tilt table design capable of tilting both left and right, enabling Flynn to assemble their walls on either side efficiently. To demonstrate the feasibility of this concept, Kear provided design drawings, photos, and videos of a similar project completed in the past. Impressed by the concept, Flynn tasked Kear Fabrication with designing a fully customized table to meet their specific needs.
During the design phase, the Kear team worked closely with Flynn’s team through weekly meetings, held both virtually and in person, to ensure the design met their exact requirements. This open collaboration led to a major insight: to fully optimize the production line and maximize the benefits of the new tilt table, Flynn needed to replace their existing conveyor tables.
Kear Fabrication quickly developed and proposed designs for the additional conveyor tables. Flynn approved the designs, greenlighting the production of a complete assembly solution.
Execution
As soon as the designs were finalized, Kear Fabrication began production, maintaining weekly meetings to ensure the process stayed on track and aligned with Flynn’s expectations. During the final phases of assembly, Flynn’s team visited Kear’s facilities to inspect the equipment and suggest minor tweaks, ensuring every detail met their production needs.
To guarantee seamless integration, Flynn provided sample products to test the equipment. With Flynn’s team present during testing, adjustments were made to confirm the equipment's reliability and performance. Once testing was completed, the equipment was shipped to Flynn’s facility, where Kear Fabrication assisted with installation to ensure smooth setup and operation.
Results
The collaboration between Flynn Canada and Kear Fabrication resulted in a fully optimized production line featuring the custom tilt table and newly designed conveyor tables. The new equipment allowed Flynn to handle their large and heavy wall products with ease, enhancing efficiency and ergonomics across their production process.
The project demonstrated Kear Fabrication’s ability to deliver tailored solutions through collaboration, innovation, and attention to detail, reinforcing its reputation as a trusted partner in the Fenestration Industry. Flynn Canada now operates a streamlined and efficient production line, achieving their goals with equipment designed to meet their exact needs.