From Assembly Headaches to Seamless Flow: How Intelligent Automation Built Predictable Performance for Xerox/Tektronix

The Client: Xerox/Tektronix

Tektronix (now part of Xerox) operated a high-precision final assembly operation in Wilsonville, Oregon for four-color printers requiring configuration and testing before shipment. The facility needed to balance product customization, throughput, and floor efficiency in a fast-moving manufacturing environment.

To scale this operation without losing control, Tektronix partnered with FloStor to redesign final assembly flow around intelligent movement, workstation sequencing, and real-time routing logic.

The Challenge

Assembly Sequence Complexity: Each printer required specific configuration steps, and manual routing made it difficult to ensure units reached the right station in the right order.
Floor Congestion and Delay: Forklift-dependent movement between work areas created traffic conflicts, pallet wait time, and stop-and-start production flow.
Footprint Constraints: The operation needed to increase control and throughput while staying within a limited facility footprint.
Demand Surge Volatility: End-of-quarter spikes exposed the limits of a rigid process that could not easily reprioritize workflow to match changing order demand.

The Solution

FloStor engineered an intelligent down-and-back conveyor architecture that converted final assembly from a manually coordinated process into a controlled, data-driven workflow. Instead of pushing units forward in a fixed sequence, the system dynamically routed each printer based on required work content.

Using slave pallets, zoned accumulation, sensors, and controls logic, FloStor built a system that delivered each unit to the right workstation at the right time while minimizing congestion and preserving production floor space.

Systems Used

Down-and-Back Powered Roller Conveyor: A 136-foot conveyor layout designed to move printers through final assembly in a controlled loop without excessive floor travel.
127-Zone Intelligent Accumulation Control: Independently controlled power zones enabled precise starts, stops, spacing, and station delivery for each slave pallet.
Slave Pallet Work Carrier System: Mobile pallet platforms carried printers through customization and testing stages while preserving orientation and handling consistency.
Photo-Eye Sensor and Reflective Slider Routing: Pallet destination signals and occupancy feedback informed control software to route units to the correct workstation sequence.
Automated Transfers and Ergonomic Workstations: Chain-driven transfers, ball transfer tables, and ergonomic lift points improved workstation access and reduced manual strain.

Xerox Tektronics - Scheme — Boxed printers arrive for final assembly at the unpacking station where vacuum hoists transfer them to the intelligent conveyor line for delivery to various workstations starting with control board installation. At the end of the line, the printer is transferred to the parallel intelligent conveyor for the return trip to the final workstations leading to packaging and shipping. There, completed printers are repacked in the boxes they originally arrived in and labeled for final shipment.

The Power of Integration in Action

FloStor’s integration work unified mechanical movement, sensor feedback, pallet routing, transfer logic, and workstation ergonomics into one coordinated execution model. The result was continuous flow with controlled accumulation rather than forklift-driven queueing.

Because the system could manage unit order dynamically, Tektronix gained the ability to reprioritize and sequence work to meet daily order mix and end-of-quarter demand surges without sacrificing predictability.

“As a result, [the system] has the ability to manage the process in whatever order needed to meet the day’s orders as well as accommodate surges in throughput at the end of the quarter.” – Doug Henkle, Manufacturing Engineer

The Results

Tektronix transformed final assembly from a manually coordinated bottleneck into a controlled, high-visibility workflow built for customization and volume variability. The system increased process discipline while preserving footprint efficiency in a demanding manufacturing environment.

By shifting from forklift-heavy movement to intelligent zoned transport, the facility improved sequence control, reduced congestion risk, and gained flexibility to respond to changing order priorities.

Key Outcomes

Flow Control Scale: 127 independently controlled conveyor power zones enabled precise unit-by-unit routing and accumulation management
Line Architecture: 136-foot intelligent down-and-back conveyor system connected final assembly stages in one coordinated path
Footprint Efficiency: Full system delivered within a compact 9,700 sq ft assembly footprint
Demand Responsiveness (Qualitative): Workflow sequencing could be reprioritized to handle daily order mix changes and end-of-quarter surges

Why This Worked

This implementation succeeded because FloStor designed the process as an integrated control system, not a conveyor installation. Every movement decision was tied to workstation needs, system occupancy, and order sequence priorities.

End-to-End Integration: Transport, routing, transfer logic, and controls software were engineered as one workflow engine, eliminating fragmented handoffs.
Precision Without Overcomplexity: A practical sensor-and-slider routing model delivered dynamic sequencing capabilities without introducing operational fragility.
Scalable Control in Limited Space: High zone density and compact line design improved throughput control while protecting valuable floor area.
Operator and Workflow Enablement: Ergonomic transfer and workstation design reduced handling friction and allowed teams to focus on value-added assembly work.

Related Services

System Integration and Controls Engineering
Zoned Conveyor and Accumulation Design
Workstation Flow and Transfer Automation
Installation, Commissioning, and Lifecycle Support

Precision on the Line: How Tektronix Turned Printer Assembly into a High-Performance Workflow