{"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":"2026-06-19T23:29:43","modified_gmt":"2026-06-19T23:29:43","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: Silicon Graphics (SGI)<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Silicon Graphics, Inc. (SGI), founded in 1981, was a leading manufacturer of advanced graphics-focused computer systems with global operations in California, Switzerland, and Japan. As output demand accelerated, SGI needed to increase production scale without sacrificing model flexibility or product quality.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">SGI partnered with FloStor to modernize end-to-end manufacturing flow and consolidate previously split operations into a more efficient, high-control environment.<\/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>Manual Handling and Ergonomic Risk:<\/strong> Teams manually moved heavy boxes (up to 40 lbs.) across key steps, creating safety strain and slowing throughput.<\/li>\n\n\n\n<li><strong>Throughput Ceiling:<\/strong> The existing process was maxed at roughly 100 to 150 units per day, well below projected growth requirements.<\/li>\n\n\n\n<li><strong>Fragmented Multi-Building Workflow:<\/strong> High-end and low-end lines were distributed across two facilities totaling 165,000 sq ft, adding transport friction and process complexity.<\/li>\n\n\n\n<li><strong>Model Volatility and Reconfiguration Needs:<\/strong> Short product life cycles required a flexible system that could quickly adapt to changing workstation and testing requirements.<\/li>\n\n\n\n<li><strong>Testing and Burn-In Bottlenecks:<\/strong> Manual offloading and reloading for long burn-in windows (10 to 48 hours) introduced delays, handling risk, and avoidable intervention.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">The Solution<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">FloStor designed and integrated a multi-phase conveyor architecture that connected assembly, burn-in, final test, pack-out, and shipping staging into one coordinated production flow. Rather than adding isolated equipment, the project reengineered how units moved, powered, and queued through each stage.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The implementation consolidated operations into SGI&#8217;s 100,000 sq ft low-end facility and introduced control-ready infrastructure to scale output while preserving line flexibility.<\/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>Elevated Conveyor Highways:<\/strong> Off-floor conveyor routing improved personnel and vehicle traffic conditions while maintaining continuous product movement.<\/li>\n\n\n\n<li><strong>Integrated Power Pallets:<\/strong> Specialized powered pallets kept units on-conveyor through testing and burn-in stations, eliminating repeated manual loading and unloading.<\/li>\n\n\n\n<li><strong>Modular Reconfigurable Test Stations:<\/strong> Movable station architecture enabled fast adaptation to new model requirements and changing line priorities.<\/li>\n\n\n\n<li><strong>Vertical Lifts and Multi-Level Conveyance:<\/strong> Integrated lift and incline systems connected production phases across elevations without forklift dependency.<\/li>\n\n\n\n<li><strong>Flow Rack Shipping Staging and Take-Away Conveyance:<\/strong> Finished goods were staged, pulled, and routed to shipping with automated transfer continuity.<\/li>\n\n\n\n<li><strong>Proven Hytrol Platform and Integrated Controls:<\/strong> SPA\/SP conveyors, pop-up transfers, and controls logic (with Serra Systems) delivered reliable orchestration across all phases.<\/li>\n<\/ul>\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<h2 class=\"wp-block-heading\">The Power of Integration in Action<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">FloStor&#8217;s integrator role unified mechanical handling, electrical systems, controls software, and workstation design into one execution model. The result was an end-to-end workflow where units could move from assembly through burn-in and final test without the repetitive manual interruptions that had constrained output.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Crucially, installation was phased to avoid production shutdown, allowing SGI to keep shipping while transitioning to the new architecture.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">The Results<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">SGI converted a labor-intensive, space-constrained operation into a scalable and highly reliable production system built for both growth and model variability. The integrated flow removed critical bottlenecks and enabled sustained high-volume performance.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">With conveyor-based continuity and modular station logic, the operation gained the flexibility to handle new product introductions while maintaining tighter process control.<\/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>Throughput Increase:<\/strong> Capacity rose from approximately 100 to 150 units\/day to around 400 units\/day across three product lines<\/li>\n\n\n\n<li><strong>Space Productivity:<\/strong> Consolidated from 165,000 sq ft across two buildings into a 100,000 sq ft operation while tripling output<\/li>\n\n\n\n<li><strong>Implementation Continuity:<\/strong> System installed in phased rollout under six months with no production shutdown required<\/li>\n\n\n\n<li><strong>Operational Reliability:<\/strong> Platform supported extended high-demand operation, including near-24\/7 peak usage with minimal disruption<\/li>\n<\/ul>\n\n<\/div>\n\n<\/div>\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<h2 class=\"wp-block-heading\">Why This Worked<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">This project succeeded because SGI and FloStor optimized the full manufacturing sequence rather than automating isolated tasks. Every phase was designed for continuity, flexibility, and production resiliency.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>End-to-End Process Integration:<\/strong> Assembly, burn-in, testing, pack-out, and shipping were connected into a unified flow with fewer handoff failures.<\/li>\n\n\n\n<li><strong>Design for Flexibility:<\/strong> Modular stations and reconfigurable paths supported frequent model changes without full-line redesign.<\/li>\n\n\n\n<li><strong>Operator Safety and Efficiency:<\/strong> Power pallet handling reduced repetitive heavy lifting and improved ergonomic conditions at scale.<\/li>\n\n\n\n<li><strong>Scalable Architecture with Proven Components:<\/strong> Mature conveyor technologies combined with custom integration created reliability without sacrificing growth capacity.<\/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 branching from the main line. The system delivered triple manufacturing capacity in less space.<\/figcaption><\/figure>\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 Lift-Based Manufacturing Flow Design<\/li>\n\n\n\n<li>Modular Workstation and Test-Line Optimization<\/li>\n\n\n\n<li>Installation, Commissioning, and Lifecycle Support<\/li>\n<\/ul>\n\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":[26,30,22],"tags":[35,31,46,58,50,44],"class_list":["post-227","case-study","type-case-study","status-publish","has-post-thumbnail","hentry","category-electronics-technology","category-industry","category-intelligent-motion","tag-asrs","tag-conveyors","tag-ergonomics","tag-high-volume-throughput","tag-scalability","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>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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