Dishwasher Inner Casing Storage Line

Prosimtech Engineering provides full automation, high speed, and traceability in production processes with the Dishwasher Inner Body Stock Line Project designed for dishwasher manufacturing plants.

This system fully covers the processes of automatically collecting dishwasher inner bodies from clinching stations, storing and managing them, and transferring them to assembly lines in an end-to-end automated workflow.

Project Description

This project was designed as a fully automated storage and transfer system, eliminating the need for manual handling.
The inner casings leaving the production line are managed by high-speed conveyors, elevator lift systems, buffer areas,and RFID-based tracking technology.
With 26 storage lanes and a two-level conveyor structure, the system can actively store up to 576 casings simultaneously.

The system provides dynamic stock management according to production intensity, recognizes different body types (SKUs), and automatically directs each part to the correct assembly line.

System Components

• Feeding Conveyors:
  Roller and belt conveyors operating at 1 m/s, feeding outputs from the seaming machines within a 14-second cycle time.

• Distribution Conveyors:
  Direct inner casings to appropriate storage lanes with a 6-second cycle time.

• Storage Lanes:
  26 independent storage lines, each with a capacity of 11 pallets (22 casings), operating based on an SKU-based stock algorithm.

• Lifts:
  A dual-level lift system that manages empty pallet return on the lower level and full pallet transfer on the upper level, with a maximum cycle time of 20 seconds.

• By-pass Conveyor:
  Allows inner casings to be transferred directly to the assembly line when storage is not required.

• Manual Unloading Station:
  Enables safe removal of defective or quality-check products from the system.

• Pallet Return Line:
  Chain-driven lower-level conveyors automatically return empty pallets to the beginning of the line.

Automation and Software Infrastructure

The entire control system is based on Siemens S7-1500 PLC and managed via a Profinet communication network.
All movements, stock statuses, and fault notifications are monitored through the WinCC SCADA interface.

The system is fully integrated with Arçelik’s existing production data infrastructure, including ARBAR, SAP, and the Body Traceability System.
Each pallet is equipped with Balluff RFID tags or barcode sensors, allowing real-time tracking of each casing’s stock and movement data.

Mechanical Specifications

• Conveyor Speed: 1 m/s

• Storage Capacity: 576 casings

• Pallet Size: 900 × 600 mm

• Materials: Galvanized steel structure, aluminum guide profiles

• Cycle Time: 6 seconds per module

• Lift Height Difference: Up to 5 meters

• Sensor Brands: SICK, Balluff, Keyence

• Safety Standards: EN ISO 13849-1 and CE 2006/42/EC compliant

Key Advantages

• Fully automated inner casing flow within the production line

• Up to 40% increase in space efficiency

• Operator-free operation with low error rates

• RFID-based digital stock management and traceability

• High-speed production support with by-pass conveyors

• Low operating cost with energy-efficient motor systems

• Modular design ensures easy maintenance and system continuity

Prosimtech Engineering’s Contribution

Prosimtech Engineering completed all mechanical, electrical, and automation integrations of this system with its in-house engineering team.
Scope of work included:

• 3D mechanical design

• Conveyor manufacturing and on-site installation

• Electrical panel design and PLC programming

• SCADA software development

• SAP and traceability system integration

• Commissioning and operator training

All phases were delivered on a turnkey basis.

This project stands out as one of the most advanced automatic inner casing storage systems used in white goods manufacturing in Turkey.