{"id":227,"date":"2025-05-19T19:40:14","date_gmt":"2025-05-19T19:40:14","guid":{"rendered":"https:\/\/api.flostor.com\/backend\/?post_type=case-study&#038;p=227"},"modified":"2025-05-19T19:40:15","modified_gmt":"2025-05-19T19:40:15","slug":"tripling-throughput-halving-the-footprint-sgis-smart-leap-into-scalable-automation","status":"publish","type":"case-study","link":"https:\/\/api.flostor.com\/backend\/case-study\/tripling-throughput-halving-the-footprint-sgis-smart-leap-into-scalable-automation\/","title":{"rendered":"Tripling Throughput, Halving the Footprint: SGI\u2019s Smart Leap into Scalable Automation"},"content":{"rendered":"\n<h1 class=\"wp-block-heading\">Fueling High-End Performance: How Silicon Graphics Integrated Automation for Control and Flexibility<\/h1>\n\n\n\n<h2 class=\"wp-block-heading\">The Client<\/h2>\n\n\n\n<p>Silicon Graphics, Inc. (SGI), founded in 1981, was a leading public company specializing in the production of state-of-the-art computers primarily used for graphics. With manufacturing facilities in Mountain View, CA, Switzerland, and Japan, and employing over 4,000 people, SGI was experiencing significant growth and high output demands.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">The Challenge<\/h2>\n\n\n\n<p>As Silicon Graphics grew, the need to maintain high production volumes while simultaneously producing a wide variety of high-end and low-end computer models within the <em>same<\/em> system became paramount. Their existing processes, which involved separating high-end and low-end production across two buildings totaling 165,000 square feet, were heavily reliant on manual handling and proved to be significant bottlenecks.<\/p>\n\n\n\n<p>Key challenges included:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Manual Handling &amp; Ergonomic Risk:<\/strong> Production was highly labor-intensive, involving substantial manual lifting of heavy boxes (up to 40 lbs. each), posing safety concerns for employees who might lift hundreds of systems daily.<\/li>\n\n\n\n<li><strong>Information Management:<\/strong> The increasing volume of products necessitated a more automated way to handle the associated production data and tracking.<\/li>\n\n\n\n<li><strong>Scaling Production:<\/strong> SGI projected a need to triple their production output, a feat impossible with their existing manual processes and forklift-dependent material movement.<\/li>\n\n\n\n<li><strong>Maintaining Flexibility:<\/strong> Despite the need for automation, a critical requirement was the ability to adapt quickly to new computer models and reconfigure production lines due to short product life cycles.<\/li>\n\n\n\n<li><strong>Inefficient Workflow:<\/strong> The manual process of moving units off and onto conveyor lines for testing, burn-in (which could last 10-48 hours), and quality control stations created significant delays and required manual intervention like lifting or using cranes.<\/li>\n<\/ul>\n\n\n\n<p>As Jim Mullen at Silicon Graphics described, their system was &#8220;maxed out&#8221; at 100-150 units a day, severely limiting their growth potential.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">The Solution<\/h2>\n\n\n\n<p>Recognizing the limitations of their manual processes and the need for a strategic shift to accommodate growth, enhance safety, and ensure flexibility, Silicon Graphics partnered with a trusted material handling system integrator. FloStor Engineering, having successfully completed previous projects with SGI, was brought in from the concept phase to completion.<\/p>\n\n\n\n<p>FloStor, acting as the system architect, collaborated with SGI to design a comprehensive, automated conveyor system. This solution wasn&#8217;t just about adding equipment; it was about engineering a seamless workflow that integrated production, testing, burn-in, quality control, packing, and shipping into a single, efficient process. The project involved consolidating operations from two buildings into the existing 100,000 sq. ft. low-end facility.<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"893\" height=\"544\" src=\"https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/sgi-3-opt.jpg\" alt=\"SGI - Conveyors\" class=\"wp-image-230\" srcset=\"https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/sgi-3-opt.jpg 893w, https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/sgi-3-opt-300x183.jpg 300w, https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/sgi-3-opt-768x468.jpg 768w\" sizes=\"auto, (max-width: 893px) 100vw, 893px\" \/><\/figure>\n\n\n\n<p>The integrated system was designed with key innovations:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Elevated Conveyor Lines:<\/strong> To improve traffic flow on the floor, the conveyor lines were strategically placed off the ground.<\/li>\n\n\n\n<li><strong>Integrated Power Pallets:<\/strong> A crucial innovation was the use of special power pallets designed to carry the computer units. These pallets had their own power connectors that could &#8220;snap in&#8221; at every test station along the line, eliminating the need to manually remove and replace units from the conveyor.<\/li>\n\n\n\n<li><strong>Modular Test Stations:<\/strong> Test stations were designed to be modular, allowing them to be easily moved and reconfigured to different lines, ensuring the required flexibility for rapidly changing product models.<\/li>\n\n\n\n<li><strong>Multi-Phase Workflow:<\/strong> The system was implemented in three integrated phases:\n<ol class=\"wp-block-list\">\n<li><strong>Assembly &amp; Burn-in:<\/strong> Workstations fed completed units on power pallets onto a &#8220;main highway&#8221; conveyor (Hytrol SPA). Vertical lifts and more SPA conveyors transported units to burn-in.<\/li>\n\n\n\n<li><strong>Final Testing &amp; Pack Out:<\/strong> After burn-in, units returned to the &#8220;main highway&#8221; for final testing (again without leaving the pallet\/conveyor) and ascended via vertical lift to the second phase for packaging. SP and incline belts moved units to packaging, with a holding area for finished product before boxing. Pallets were returned to the assembly area via conveyor.<\/li>\n\n\n\n<li><strong>Shipping Staging:<\/strong> Packaged computers were pulled from a large flow rack system onto a take-away conveyor, transported overhead, and lowered by a vertical lift to the loading area for palletizing and shipping.<\/li>\n<\/ol>\n<\/li>\n\n\n\n<li><strong>Proven Technologies:<\/strong> The final system design, refined through simulation from six initial ideas, utilized proven conveyor technologies (Hytrol SPA, SP, incline belts, pop-up O-ring transfers) and integrated them with custom elements and control software (by Serra Systems).<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">The Results<\/h2>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"900\" height=\"431\" src=\"https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/sgi-4-opt.jpg\" alt=\"SGI - Vertical Lift\" class=\"wp-image-231\" srcset=\"https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/sgi-4-opt.jpg 900w, https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/sgi-4-opt-300x144.jpg 300w, https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/sgi-4-opt-768x368.jpg 768w\" sizes=\"auto, (max-width: 900px) 100vw, 900px\" \/><\/figure>\n\n\n\n<p>The implementation of the integrated conveyor system transformed Silicon Graphics&#8217; operations, delivering significant, quantifiable benefits and overcoming their previous limitations. These included:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Dramatic Increase in Throughput:<\/strong> The facility&#8217;s capacity surged from a maximum of 100-150 units a day to approximately 400 units a day across three product lines, with potential for further increase.<\/li>\n\n\n\n<li><strong>Tripled Output in Reduced Space:<\/strong> By consolidating into a 100,000 sq. ft. building, SGI was able to produce three times the number of boxes compared to their previous 165,000 sq. ft. setup.<\/li>\n\n\n\n<li><strong>Reduced Manual Handling &amp; Improved Safety:<\/strong> The system significantly decreased the need for employees to manually lift and carry heavy boxes, addressing critical safety concerns and reducing physical strain.<\/li>\n\n\n\n<li><strong>Enhanced Flexibility:<\/strong> The modular design, reconfigurable lines, and integrated power pallets allowed SGI to quickly adapt the system to new product models with short life cycles.<\/li>\n\n\n\n<li><strong>Seamless Workflow &amp; Eliminated Bottlenecks:<\/strong> The automated movement of units on power pallets through testing and burn-in eliminated previous manual steps and traffic jams on the line.<\/li>\n\n\n\n<li><strong>Impressive ROI:<\/strong> Despite the investment, the conveyor line was considered cost-effective, contributing to a period where sales increased significantly from $700 million to over $1 billion.<\/li>\n\n\n\n<li><strong>Zero Production Downtime During Installation:<\/strong> Crucially, the system was installed in phases over less than six months <em>without<\/em> requiring a shutdown of existing production, allowing SGI to &#8220;just moved everything and kept producing stuff.&#8221;<\/li>\n\n\n\n<li><strong>High Reliability:<\/strong> The system proved remarkably reliable, running up to 24\/7 during peak times with minimal issues, primarily operator errors or minor maintenance needs. As Jim Mullen stated, &#8220;It&#8217;s become a non-entity, it&#8217;s just like the lights going on at night, it just happens.&#8221;<\/li>\n<\/ul>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"900\" height=\"625\" src=\"https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/sgi2-scheme-opt.jpg\" alt=\"Silicon Graphics Inc. (SGI) - Scheme\" class=\"wp-image-226\" srcset=\"https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/sgi2-scheme-opt.jpg 900w, https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/sgi2-scheme-opt-300x208.jpg 300w, https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2025\/05\/sgi2-scheme-opt-768x533.jpg 768w\" sizes=\"auto, (max-width: 900px) 100vw, 900px\" \/><figcaption class=\"wp-element-caption\">A conveyor highway delivers work-in-process to highly-reconfigurable, modular workstations that branch off of the main line. The system has three times the manufacturing capacity as before in less space.<\/figcaption><\/figure>\n\n\n\n<p>By partnering with FloStor Engineering for a comprehensive, integrated solution, Silicon Graphics successfully navigated the challenges of rapid growth, diverse product lines, and the need for operational flexibility. They transformed a labor-intensive, space-constrained operation into a high-throughput, safe, and adaptable automated powerhouse, securing a significant return on their investment and establishing a foundation for future growth.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Faced with skyrocketing demand and manual limitations, Silicon Graphics partnered with FloStor to engineer a modular, high-efficiency system that tripled output, reduced physical strain, and consolidated operations\u2014all without halting production.<\/p>\n","protected":false},"featured_media":229,"template":"","meta":{"_acf_changed":false},"categories":[],"tags":[],"class_list":["post-227","case-study","type-case-study","status-publish","has-post-thumbnail","hentry"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.2 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Tripling Throughput, Halving the Footprint: SGI\u2019s Smart Leap into Scalable Automation - Flostor<\/title>\n<meta name=\"description\" content=\"Silicon Graphics transformed its manual, space-constrained operation into a high-throughput, automated powerhouse\u2014tripling output, improving safety, and ensuring future-ready flexibility without disrupting production. 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