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- Large parts logistics
Executive summary
General Electric (GE) in Birr, Switzerland, sought to optimize its supply chain by replacing repeatedly used wooden crates with a more efficient solution. GE collaborated with Utz to develop reusable, space-saving KLAPA pallet containers for transporting raw rotor blades from the foundry to further processing and storage at GE and on to the customer. This innovative solution has significantly improved the handling, transportation, and durability of the rotor blades, enhancing overall efficiency.
The client
General Electric (GE) in Birr, Switzerland, is a leading manufacturer of rotors for gas and steam turbines and generators. The company conducts all manufacturing stages, from the production of individual rotor blades in various sizes to the finished rotor weighing up to 400 tons. All Swiss products are intended for export.
The challenge
GE faced the challenge of transporting raw rotor blades from the foundries in repeatedly used wooden crates, which became very dirty, damp, and unsightly over time. Transporting the finished goods to the customer required the repeated manufacture of new wooden crates. GE sought a better solution that would be reusable, space-saving, and durable for transport from the foundry to further processing and storage at GE and on to the customer.
The solution
Utz developed a comprehensive solution by providing foldable KLAPA pallet containers in the basic dimensions 1200 × 800 mm and 1200 × 1000 mm in various heights. For very long rotor blades, the height of the KLAPA can be adjusted by attaching up to three extension frames. Each KLAPA is covered with a robust lid for transport. Inside, the blades are fixed in place with plug-in separators and special thermoformed interim layers, allowing for upright transport. One KLAPA can be loaded with up to 800 kg. The KLAPA is a standard Utz product, but the separators, top frames, and interim layers were developed especially for this project. The advantage of the KLAPA compared to the earlier wooden crates is its space-saving storage and transportability as well as its durability, as it can be washed and repaired.
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View a 3D model of KLAPA container
Implementation process
- Initial consultation: GE and Utz assessed the system requirements and objectives.
- Container design and production: Utz designed and manufactured the KLAPA containers tailored to GE's specific requirements.
- Continuous support: Utz provided ongoing support, including the development of separators, top frames, and interim layers for the project.
Results
The collaboration between GE and Utz led to significant operational improvements:
- Efficient handling and transportation: The KLAPA containers enabled space-saving storage and transportability, improving the handling and transportation of rotor blades.
- Durability and sustainability: The KLAPA containers can be washed and repaired, reducing the need for repeated manufacture of new wooden crates and contributing to GE's sustainability efforts.
- Enhanced process management: The custom separators, top frames, and interim layers allowed for secure and efficient transport of rotor blades in an upright position.
Our cooperation with the project managers at Georg Utz AG was very good and constructive right from the start.
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