How Ascend Communications Increased Telecom Production Flow with Integrated Conveyor Automation
The Client: Ascend Communications
Ascend Communications manufactured telecom equipment in a high-volume, high-precision environment where throughput reliability and shipment readiness were critical. Operating from a 100,000-square-foot facility, Ascend needed stronger internal flow control to support growth without compromising safety or production flexibility.
FloStor partnered with Ascend to redesign material movement from receiving through production and shipping using a systems-integration approach.
The Challenge
- Manual Flow Bottlenecks: Forklift and manual handling dependencies slowed movement of heavy work-in-process units.
- Floor Congestion Risk: Dense traffic patterns increased process friction and safety exposure in active production zones.
- Throughput Constraints: Existing handling methods limited pace across assembly and downstream transfer stages.
- Testing-to-Shipping Friction: Lengthy validation steps required more controlled transfer to final pack and outbound flow.
- Scalability Pressure: Growth targets demanded a flexible architecture that could absorb peak and low-demand cycles.
The Solution
FloStor engineered a conveyor-centered material handling network to replace fragmented manual movement and support continuous line flow. The design linked receiving, production cells, final packing, and shipping transfer into one coordinated operating sequence.
The architecture included a U-shaped production flow model with operator-directed routing control and an elevated takeaway conveyor for efficient post-test product movement to shipping.
Systems Used
- Powered Conveyor Transport Network: Automated in-plant movement for palletized work-in-process and finished goods.
- U-Shaped Workstation Flow Design: Multi-station routing supported pacing flexibility and line balancing.
- Operator-Directed Routing Controls: Station-level control points directed load transfer based on real-time needs.
- Elevated Takeaway Shipping Conveyor: Dedicated post-pack flow reduced interference with active production zones.
- Barcode-Labeled Carton Transfer Process: Final packing identification supported downstream shipping accuracy.
The Power of Integration in Action
FloStor’s integrator role connected equipment, workflow logic, and operator behavior into one synchronized material flow model. Instead of isolated upgrades, the solution aligned upstream and downstream dependencies to keep line movement stable across changing production conditions.
This created operational resilience during both end-of-quarter demand surges and slower cycle periods while preserving manufacturing efficiency.
The Results
Ascend improved throughput, reduced floor congestion, and strengthened safety by replacing manual transfer dependence with an integrated conveyor flow system. The upgraded model supported higher output while maintaining process control through long test and assembly cycles.
The facility also gained flexibility to scale workstation count and expand future line capacity without redesigning core flow infrastructure.
Key Performance Gains
- Production Throughput Increase: Line operations achieved output capability exceeding 85 units per shift
- Congestion Reduction: Conveyor-based transfer reduced forklift traffic and improved floor flow predictability
- Safety Improvement: Lower manual handling burden reduced risk exposure in heavy-equipment movement zones
- Scalability Readiness: Facility gained flexibility for additional workstations and future line expansion
Why This Worked
This project succeeded because Ascend and FloStor approached performance as a system-level flow challenge, not a standalone equipment install. Workstation routing, transfer logic, packing flow, and shipping handoff were designed to reinforce each other.
- End-to-End Flow Engineering: Receiving, assembly, testing, and shipping were integrated as one operating path.
- Operator-Guided Flexibility: Station-level control supported pacing adjustments without destabilizing throughput.
- Safety Built into Movement Design: Reduced forklift dependence improved both operational clarity and workplace conditions.
- Scale-Ready Infrastructure: The core architecture supported growth without full process rework.
Related Services
- Manufacturing Conveyor and Material Flow System Integration
- Workstation Routing and Line Balancing Design
- Packaging and Shipping Transfer Optimization
- Scalable Production Infrastructure Planning and Support