{"id":209,"date":"2025-05-14T20:08:49","date_gmt":"2025-05-14T20:08:49","guid":{"rendered":"https:\/\/api.flostor.com\/backend\/?post_type=case-study&#038;p=209"},"modified":"2026-06-19T23:52:39","modified_gmt":"2026-06-19T23:52:39","slug":"smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor","status":"publish","type":"case-study","link":"https:\/\/api.flostor.com\/backend\/case-study\/smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor\/","title":{"rendered":"Smart Automation in Tight Quarters: Zhone Technologies Optimizes Telecom Manufacturing with FloStor"},"content":{"rendered":"\n<h1 class=\"wp-block-heading\">Navigating Complexity: How Agile Automation Powers Telecom Production in Tight Spaces<\/h1>\n\n\n\n<h2 class=\"wp-block-heading\">The Client: Zhone Technologies<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Zhone Technologies manufactures sophisticated telecommunications systems that support high-speed network infrastructure. While high-volume production is outsourced, Zhone operates a compact 15,000 sq ft in-house facility in Oakland, California to support new product introduction, validation, and production readiness.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This footprint strategy required an internal handling system that could deliver high flexibility, precise routing, and efficient use of limited space.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">The Challenge<\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>High Product Variation:<\/strong> Product families followed different production and test paths, making fixed linear routing impractical.<\/li>\n\n\n\n<li><strong>Manual Cart-Based Movement:<\/strong> Technician-pushed carts created stop-and-start flow, inconsistent handoffs, and avoidable handling delays.<\/li>\n\n\n\n<li><strong>Technician and Unit Wait Time:<\/strong> Products waited for cells, and technicians waited for product arrival, reducing skilled labor utilization.<\/li>\n\n\n\n<li><strong>Ergonomic Strain:<\/strong> Manual handling of units weighing over 100 lbs introduced safety risk and physical burden.<\/li>\n\n\n\n<li><strong>Space Pressure:<\/strong> Carts and unmanaged WIP consumed valuable floor area in an intentionally compact manufacturing space.<\/li>\n<\/ul>\n\n\n\n<blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\">\n<p class=\"wp-block-paragraph\">&#8220;Our manufacturing strategy is based on outsourcing&#8230; Outsourcing allows us to focus on our core competencies. So we do not need a large manufacturing space.&#8221; &#8211; Ebrahim Abbasi, Vice President of Manufacturing<\/p>\n<\/blockquote>\n\n\n\n<h2 class=\"wp-block-heading\">The Solution<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">FloStor engineered a compact, software-directed material handling backbone that replaced manual cart movement with coordinated conveyor and transfer logic. The system was designed to route diverse product types dynamically while preserving human control at key decision points.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Rather than forcing one rigid path, the architecture supported configurable routing, pull-based test-cell feeding, and transparent WIP visibility to keep flow balanced in limited space.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Systems Used<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Roller Conveyor Paths:<\/strong> Core transport lanes moved systems between assembly, staging, and test processes with controlled handoffs.<\/li>\n\n\n\n<li><strong>Pop-Up Ball Table Transfers:<\/strong> Workstation-level transfer points enabled ergonomic rotation and multi-side access during tasks such as PCB insertion.<\/li>\n\n\n\n<li><strong>Hydraulic Lift Table and Lift-Assist Carts:<\/strong> Mechanical assist tools reduced manual lifting demands for heavy telecom units.<\/li>\n\n\n\n<li><strong>Sortation Transfer Vehicle (STV):<\/strong> A compact software-controlled vehicle running on a 72-foot track handled intelligent delivery and takeaway between test cells.<\/li>\n\n\n\n<li><strong>Programmable Pushbutton Routing Interface:<\/strong> Operators initiated controlled routing requests while software managed transaction state and destination execution.<\/li>\n\n\n\n<li><strong>Bidirectional Conveyors for NPI Flexibility:<\/strong> Dedicated routes for unconventional development units enabled movement to and from any required process point.<\/li>\n<\/ul>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"900\" height=\"512\" src=\"https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/zhone-scheme-opt.jpg\" alt=\"Zhone Technologies - Scheme\" class=\"wp-image-211\" srcset=\"https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/zhone-scheme-opt.jpg 900w, https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/zhone-scheme-opt-300x171.jpg 300w, https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/zhone-scheme-opt-768x437.jpg 768w\" sizes=\"auto, (max-width: 900px) 100vw, 900px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"900\" height=\"531\" src=\"https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/zhone-assembly-opt.jpg\" alt=\"Zhone Technologies - Assembly\" class=\"wp-image-212\" srcset=\"https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/zhone-assembly-opt.jpg 900w, https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/zhone-assembly-opt-300x177.jpg 300w, https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/zhone-assembly-opt-768x453.jpg 768w\" sizes=\"auto, (max-width: 900px) 100vw, 900px\" \/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">The Power of Integration in Action<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">FloStor&#8217;s integration strategy connected transport hardware, routing controls, and process logic into one coordinated production support system. The STV and conveyor network were synchronized to deliver units when destinations were available, eliminating push-queue congestion at test cells.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This pull-oriented flow improved technician utilization, reduced idle WIP, and gave operations leadership clearer real-time visibility into product location and status.<\/p>\n\n\n\n<blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\">\n<p class=\"wp-block-paragraph\">&#8220;Based on past experiences with similar applications using conveyor based delivery systems, we determined that an STV would better accommodate the spikes in our production volume and eliminate the inherent bottlenecks common with conveyors.&#8221; &#8211; John Friedl, Senior Manufacturing Engineer<\/p>\n<\/blockquote>\n\n\n\n<h2 class=\"wp-block-heading\">The Results<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Zhone transformed a constrained manual transport process into a controlled, high-flexibility handling system aligned to its outsourcing-led manufacturing strategy. The new architecture improved flow predictability, reduced ergonomic burden, and increased effective testing and handling efficiency.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">By optimizing movement logic inside a small footprint, Zhone gained stronger operational control without expanding into a large in-house production model.<\/p>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-f56f613f wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column caseStudyResultsBox is-layout-flow wp-block-column-is-layout-flow\">\n<h3 class=\"wp-block-heading\">Key Performance Gains<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Compact Routing Engine:<\/strong> Software-directed STV flow delivered intelligent unit movement across a 72-foot transfer track<\/li>\n\n\n\n<li><strong>Technician Handling Reduction:<\/strong> Mechanical assist and automated movement significantly reduced manual intervention for heavy 100+ lb systems<\/li>\n\n\n\n<li><strong>Test-Cell Flow Efficiency:<\/strong> Pull-based destination calling reduced waiting at cells and improved process synchronization<\/li>\n\n\n\n<li><strong>Operational Visibility:<\/strong> Software-managed routing transactions improved real-time WIP location and status awareness<\/li>\n<\/ul>\n<\/div>\n<\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Why This Worked<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">This implementation worked because Zhone and FloStor designed for variability and space efficiency from the start. The system was built around dynamic routing and pull logic instead of rigid fixed-sequence movement.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Integration Over Fragmentation:<\/strong> Conveyors, STV transport, lift-assist handling, and controls were unified into one execution model.<\/li>\n\n\n\n<li><strong>Pull-Based Process Discipline:<\/strong> Destination-triggered movement prevented queue buildup and kept work aligned to true station availability.<\/li>\n\n\n\n<li><strong>Ergonomics as a Throughput Lever:<\/strong> Reduced physical handling improved safety and enabled more consistent technician productivity.<\/li>\n\n\n\n<li><strong>Small-Footprint Optimization:<\/strong> Intelligent routing and cart elimination converted limited floor area into a higher-value production support environment.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Related Services<\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li>System Integration and Controls Engineering<\/li>\n\n\n\n<li>Conveyor and STV Routing Architecture<\/li>\n\n\n\n<li>Ergonomic Lift-Assist and Workstation Flow Design<\/li>\n\n\n\n<li>NPI-Focused Manufacturing Flow Modernization<\/li>\n<\/ul>\n\n\n\n<div style=\"height:30px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n","protected":false},"excerpt":{"rendered":"<p>With limited space and high product variation, Zhone Technologies needed an intelligent automation solution. Partnering with FloStor, they streamlined complex workflows, boosted ergonomics, and increased efficiency\u2014proving big innovation can happen in compact environments.<\/p>\n","protected":false},"featured_media":210,"template":"","meta":{"_acf_changed":false},"categories":[26,30,22],"tags":[31,46,47,44],"class_list":["post-209","case-study","type-case-study","status-publish","has-post-thumbnail","hentry","category-electronics-technology","category-industry","category-intelligent-motion","tag-conveyors","tag-ergonomics","tag-safety","tag-system-integration"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.7 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Smart Automation in Tight Quarters: Zhone Technologies Optimizes Telecom Manufacturing with FloStor - Flostor<\/title>\n<meta name=\"description\" content=\"Discover how Zhone Technologies partnered with FloStor to optimize telecom manufacturing in a compact space using intelligent automation, improving flow, safety, and efficiency in their Oakland facility.\" \/>\n<meta name=\"robots\" content=\"noindex, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Smart Automation in Tight Quarters: Zhone Technologies Optimizes Telecom Manufacturing with FloStor - Flostor\" \/>\n<meta property=\"og:description\" content=\"Discover how Zhone Technologies partnered with FloStor to optimize telecom manufacturing in a compact space using intelligent automation, improving flow, safety, and efficiency in their Oakland facility.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/api.flostor.com\/backend\/case-study\/smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor\/\" \/>\n<meta property=\"og:site_name\" content=\"Flostor\" \/>\n<meta property=\"article:modified_time\" content=\"2026-06-19T23:52:39+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/zhone-assembly-hero.jpg\" \/>\n\t<meta property=\"og:image:width\" content=\"2560\" \/>\n\t<meta property=\"og:image:height\" content=\"1440\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/jpeg\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:label1\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data1\" content=\"4 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\\\/\\\/schema.org\",\"@graph\":[{\"@type\":\"WebPage\",\"@id\":\"https:\\\/\\\/api.flostor.com\\\/backend\\\/case-study\\\/smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor\\\/\",\"url\":\"https:\\\/\\\/api.flostor.com\\\/backend\\\/case-study\\\/smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor\\\/\",\"name\":\"Smart Automation in Tight Quarters: Zhone Technologies Optimizes Telecom Manufacturing with FloStor - Flostor\",\"isPartOf\":{\"@id\":\"https:\\\/\\\/api.flostor.com\\\/backend\\\/#website\"},\"primaryImageOfPage\":{\"@id\":\"https:\\\/\\\/api.flostor.com\\\/backend\\\/case-study\\\/smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor\\\/#primaryimage\"},\"image\":{\"@id\":\"https:\\\/\\\/api.flostor.com\\\/backend\\\/case-study\\\/smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor\\\/#primaryimage\"},\"thumbnailUrl\":\"https:\\\/\\\/api.flostor.com\\\/backend\\\/wp-content\\\/uploads\\\/2025\\\/05\\\/zhone-assembly-hero.jpg\",\"datePublished\":\"2025-05-14T20:08:49+00:00\",\"dateModified\":\"2026-06-19T23:52:39+00:00\",\"description\":\"Discover how Zhone Technologies partnered with FloStor to optimize telecom manufacturing in a compact space using intelligent automation, improving flow, safety, and efficiency in their Oakland facility.\",\"breadcrumb\":{\"@id\":\"https:\\\/\\\/api.flostor.com\\\/backend\\\/case-study\\\/smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor\\\/#breadcrumb\"},\"inLanguage\":\"en-US\",\"potentialAction\":[{\"@type\":\"ReadAction\",\"target\":[\"https:\\\/\\\/api.flostor.com\\\/backend\\\/case-study\\\/smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor\\\/\"]}]},{\"@type\":\"ImageObject\",\"inLanguage\":\"en-US\",\"@id\":\"https:\\\/\\\/api.flostor.com\\\/backend\\\/case-study\\\/smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor\\\/#primaryimage\",\"url\":\"https:\\\/\\\/api.flostor.com\\\/backend\\\/wp-content\\\/uploads\\\/2025\\\/05\\\/zhone-assembly-hero.jpg\",\"contentUrl\":\"https:\\\/\\\/api.flostor.com\\\/backend\\\/wp-content\\\/uploads\\\/2025\\\/05\\\/zhone-assembly-hero.jpg\",\"width\":2560,\"height\":1440,\"caption\":\"Zhone Technologies - Assembly\"},{\"@type\":\"BreadcrumbList\",\"@id\":\"https:\\\/\\\/api.flostor.com\\\/backend\\\/case-study\\\/smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor\\\/#breadcrumb\",\"itemListElement\":[{\"@type\":\"ListItem\",\"position\":1,\"name\":\"Home\",\"item\":\"https:\\\/\\\/api.flostor.com\\\/backend\\\/\"},{\"@type\":\"ListItem\",\"position\":2,\"name\":\"Smart Automation in Tight Quarters: Zhone Technologies Optimizes Telecom Manufacturing with FloStor\"}]},{\"@type\":\"WebSite\",\"@id\":\"https:\\\/\\\/api.flostor.com\\\/backend\\\/#website\",\"url\":\"https:\\\/\\\/api.flostor.com\\\/backend\\\/\",\"name\":\"Flostor\",\"description\":\"\",\"potentialAction\":[{\"@type\":\"SearchAction\",\"target\":{\"@type\":\"EntryPoint\",\"urlTemplate\":\"https:\\\/\\\/api.flostor.com\\\/backend\\\/?s={search_term_string}\"},\"query-input\":{\"@type\":\"PropertyValueSpecification\",\"valueRequired\":true,\"valueName\":\"search_term_string\"}}],\"inLanguage\":\"en-US\"}]}<\/script>\n<!-- \/ Yoast SEO plugin. -->","yoast_head_json":{"title":"Smart Automation in Tight Quarters: Zhone Technologies Optimizes Telecom Manufacturing with FloStor - Flostor","description":"Discover how Zhone Technologies partnered with FloStor to optimize telecom manufacturing in a compact space using intelligent automation, improving flow, safety, and efficiency in their Oakland facility.","robots":{"index":"noindex","follow":"follow","max-snippet":"max-snippet:-1","max-image-preview":"max-image-preview:large","max-video-preview":"max-video-preview:-1"},"og_locale":"en_US","og_type":"article","og_title":"Smart Automation in Tight Quarters: Zhone Technologies Optimizes Telecom Manufacturing with FloStor - Flostor","og_description":"Discover how Zhone Technologies partnered with FloStor to optimize telecom manufacturing in a compact space using intelligent automation, improving flow, safety, and efficiency in their Oakland facility.","og_url":"https:\/\/api.flostor.com\/backend\/case-study\/smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor\/","og_site_name":"Flostor","article_modified_time":"2026-06-19T23:52:39+00:00","og_image":[{"width":2560,"height":1440,"url":"https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/zhone-assembly-hero.jpg","type":"image\/jpeg"}],"twitter_card":"summary_large_image","twitter_misc":{"Est. reading time":"4 minutes"},"schema":{"@context":"https:\/\/schema.org","@graph":[{"@type":"WebPage","@id":"https:\/\/api.flostor.com\/backend\/case-study\/smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor\/","url":"https:\/\/api.flostor.com\/backend\/case-study\/smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor\/","name":"Smart Automation in Tight Quarters: Zhone Technologies Optimizes Telecom Manufacturing with FloStor - Flostor","isPartOf":{"@id":"https:\/\/api.flostor.com\/backend\/#website"},"primaryImageOfPage":{"@id":"https:\/\/api.flostor.com\/backend\/case-study\/smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor\/#primaryimage"},"image":{"@id":"https:\/\/api.flostor.com\/backend\/case-study\/smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor\/#primaryimage"},"thumbnailUrl":"https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/zhone-assembly-hero.jpg","datePublished":"2025-05-14T20:08:49+00:00","dateModified":"2026-06-19T23:52:39+00:00","description":"Discover how Zhone Technologies partnered with FloStor to optimize telecom manufacturing in a compact space using intelligent automation, improving flow, safety, and efficiency in their Oakland facility.","breadcrumb":{"@id":"https:\/\/api.flostor.com\/backend\/case-study\/smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor\/#breadcrumb"},"inLanguage":"en-US","potentialAction":[{"@type":"ReadAction","target":["https:\/\/api.flostor.com\/backend\/case-study\/smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor\/"]}]},{"@type":"ImageObject","inLanguage":"en-US","@id":"https:\/\/api.flostor.com\/backend\/case-study\/smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor\/#primaryimage","url":"https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/zhone-assembly-hero.jpg","contentUrl":"https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/zhone-assembly-hero.jpg","width":2560,"height":1440,"caption":"Zhone Technologies - Assembly"},{"@type":"BreadcrumbList","@id":"https:\/\/api.flostor.com\/backend\/case-study\/smart-automation-in-tight-quarters-zhone-technologies-optimizes-telecom-manufacturing-with-flostor\/#breadcrumb","itemListElement":[{"@type":"ListItem","position":1,"name":"Home","item":"https:\/\/api.flostor.com\/backend\/"},{"@type":"ListItem","position":2,"name":"Smart Automation in Tight Quarters: Zhone Technologies Optimizes Telecom Manufacturing with FloStor"}]},{"@type":"WebSite","@id":"https:\/\/api.flostor.com\/backend\/#website","url":"https:\/\/api.flostor.com\/backend\/","name":"Flostor","description":"","potentialAction":[{"@type":"SearchAction","target":{"@type":"EntryPoint","urlTemplate":"https:\/\/api.flostor.com\/backend\/?s={search_term_string}"},"query-input":{"@type":"PropertyValueSpecification","valueRequired":true,"valueName":"search_term_string"}}],"inLanguage":"en-US"}]}},"_links":{"self":[{"href":"https:\/\/api.flostor.com\/backend\/wp-json\/wp\/v2\/case-study\/209","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/api.flostor.com\/backend\/wp-json\/wp\/v2\/case-study"}],"about":[{"href":"https:\/\/api.flostor.com\/backend\/wp-json\/wp\/v2\/types\/case-study"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/api.flostor.com\/backend\/wp-json\/wp\/v2\/media\/210"}],"wp:attachment":[{"href":"https:\/\/api.flostor.com\/backend\/wp-json\/wp\/v2\/media?parent=209"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/api.flostor.com\/backend\/wp-json\/wp\/v2\/categories?post=209"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/api.flostor.com\/backend\/wp-json\/wp\/v2\/tags?post=209"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}