An overview of Align Production Systems, an Illinois-based manufacturer of material handling equipment.

1. Align Production Systems
Overview

2. Who We Are
• Align is a designer, manufacturer and
integrator of material handling and
manufacturing automation systems
• Our emphasis: to help our clients overcome
production obstacles and maximize
productivity by leveraging the latest
movement and positioning technologies

3. History
• 50 years of heavy load movement experience
under the Airfloat banner
• Spun off turntable and lift businesses in 2013
• Became exclusive North American partner of
Silvestrini the same year
• Now go to market under the parent company
name Align Production Systems

4. Parent Company and Brands

5. AIR BEARING EQUIPMENT

6. Airfloat

7. Who We Are
• Primarily known as a manufacturer of air-film equipment
• Innovator of the air bearing (or “air caster”)
• Enable other heavy manufacturers to better automate their
manufacturing process
• 50 years of experience

8. What is an Air Bearing?
• Pneumatic device
similar to a
hovercraft
• Compressed air
passes through
a flexible
polyurethane
diaphragm
• Forms a thin air
film beneath load
• Enables nearly
frictionless,
omnidirectional
movement
• Made of chemical- and wear-resistant material

9. Typical Air Skid Setup
• Typically deployed in circuits of
three or four (like wheels)
• Used in rigging applications and
semi-annual maintenance moves
• Kits available in wide range of
sizes and capacities
• Include a multi-port controller and
air hoses

10. Kentucky Trailer – Louisville, Ky.
Workers move 50-ft.-long, 20,000-lb. trailers by hand, in any direction.
This allows the trailers to fit in spaces too tight for fork trucks to safely
maneuver.

11. GE Transportation – Erie, Penn.
75-ft.-long, 300,000-lb. diesel locomotives float on specially designed air
transporters. The equipment helped boost output from 17 to 22
locomotives per month – a 29% gain.

12. Progress Rail – Muncie, Indiana
100-ft.-long, 500,000-lb. diesel locomotives float on specially designed
air bearing shuttle. The equipment allowed the customer to have four
times the throughput in the painting of locomotives.

13. • Progress Rail
• CNH
• Bombardier
• Caterpillar
• … and More
More Recent
Projects

14. Primary Benefits
Outstanding ROI
Low capital investment
Increase productivity
Lower energy costs
Supports Lean Manufacturing
Easily reconfigure assembly lines
No in-ground installation
Minimize wasted movement (e.g.,
attaching lifting straps, etc.)

15. Primary Benefits (cont.)
Safety
Improve ergonomics
Reduce worker strain and injury
Reduce dependence on forklifts
Maintenance
Lower maintenance costs – few
moving parts to break
Reduce floor and wall damage
Better housekeeping habits

16. Air Bearing Myths
• “It’s really loud…”
• “It creates a lot of
dust…”
• “It requires
tremendous air
pressure…”
• “It won’t work on our
floor…”
• “It’s difficult to
control…”
All Incorrect!

17. Air Bearing Requirements
• Floor – flat, level, smooth and
non-porous
• Most power-troweled concrete
floors are OK
• Easy, low-cost floor improvements
are available
• Air – most plant air systems are
suitable
• Need sufficient airflow volume and
pressure
• Air consumption is proportional to
air bearing perimeter

19. Axial Industrial Turntables

20. Some Axial Turntables:
Multi-Positional Fitted with Air-bearings
Fitted with Slewing bearings
Custom

21. Air Bearing Turntables
Available in many different sizes and capacities, with or without drive
motors. Often used for container handling in factory settings. May
include integrated lift/tilt tables or other attachments.

22. Air Bearing Turntables

23. John Deere
Photo Lab
Turntable
Pit-mounted Air Bearing Turntable

24. Ford Motor Company – Woodblock flush floor air bearing 28’ turntable
with four independent inset turntables. Designed to handle 80,000 lb
load. Electric edge drive with back up drive.
Pit-mounted Air Bearing Turntable

25. General Motors – Six-
position rack indexing
turntable, with
remote operator
control stand feeding
to controls box with
PLC for plant
interface.
Floor-mounted Air Bearing Turntable

26. Robotic Turntables – Heavy
duty glass rack turntable
designed for robotic
interface. Electric Edge
Drive.
Robotic Cell Air Bearing Turntable

27. Mechanical Slewing Bearing Turntables
Available in many different sizes and capacities,
with or without drive motors.

28. Available in many different sizes and capacities,
with or without drive motors.
Mechanical Wheeled Turntables

29. INDUSTRIAL LIFTING &
POSITIONING SOLUTIONS

30. Scissor Lift Tables
• Pneumatic & Hydraulic
Scissor Lifts
• Capacities from 2,000 lbs.
to 10,000 lbs.
• Modular design for easy
addition of container tilts or
turntables
• Available in double and
triple scissor lift models for
maximum raised height
• Electric trip bar, internal
power packs, casters and
other options available

31. Specialty Scissor Lifts
‘Super Series’ Hydraulic Lifts
• Capacities from 10,000 lbs.
to 25,000 lbs.
• Built for extreme lifting
applications
Loading Dock Lifts
• Safer and less expensive
than concrete ramps
• Work with variety of trucks
and trailers

32. Additional Safebilt Products
Container Tilts
• Capacities from 2,000 lbs.
to 6,000 lbs.
• 30⁰ and 45⁰ tilt models
• Bolt-on or standalone
operation
Pneumatic Pallet Jack
• 7,500 lb. capacity
• Spark-free operation
• Ideal for explosive or
hazardous environments

33. INDUSTRIAL POSITIONERS

34. Silvestrini N.A.
• Heavy duty welding
positioners
• Headstock & tailstock
positioners
• Two- and three-axis
industrial manipulators
• Pipe/vessel turning
rollers

35. Silvestrini N.A.
• Founded in Bologna, Italy
• 100-year history, fourth-generation owned
• Maker of hydraulic positioners, manipulators,
and turntables for welding and assembly
• Has historically gravitated toward heavy,
difficult positioning challenges
• Now available in North America in partnership
with Align Production Systems

36. Silvestrini Equipment
Pipe-Turning Rollers Three-Axis Orbital Positioners
Two-Axis Welding Positioners Three-Axis Welding Positioners

37. Two-Axis Welding Positioners
• Capacities from 400 lbs. to 40 tons
• Offer tilting and variable-speed
rotation
• Manual, motor-driven and hydraulic
tilt models available
• Positioner need not be anchored to
the floor
• Heavy-duty SA models are virtually
maintenance-free and last 30 years
or more under normal conditions
• Reduce cycle time by 45-50% over
static positioning

38. Three-Axis Welding Positioners
• Capacities from 1,000 lbs. to 40 tons
• Offer tilting, variable-speed rotation
and hydraulic lifting
• Robust 5-to-1 Factor of Safety (FoS)
• Machine feet are located behind the
table so that large pieces rotate
freely, even when table is in vertical
position (90° tilt)
• Heavy-duty AVSA models are virtually
maintenance-free and last 30 years
or more under normal conditions
• Reduce cycle time by 55-60% for
larger work pieces

39. Headstock & Tailstock Positioners
• Offer hydraulic lifting and
electric gear-motor rotation
• Capacities from 1,000 kg.
to 40 tons
• 5 to 1 Factor of Safety (FoS)
• Hydraulic safety cutoff
• Slide positioning for varying
fixture lengths
• Optional work-holding jigs
and fixtures

40. Three-Axis Orbital Positioners
• Offer rotation, lifting and
tilting
• Capacities from 1,000 kg.
to 40 tons
• 5 to 1 Factor of Safety (FoS)
• Advanced motion control
for smooth rotation
• Hydraulic safety cutoff
• Optional clamping system
(chuck)

41. Pipe-Turning Roller Positioners
• Capacities from 1,000 kg. to
90 tons
• Includes motorized driver
section and idle section
• Rotate pipes/tanks up to 8
meters in diameter and 80
meters long
• Powered by two three-
phase 380V 50Hz motors

42. Our Capabilities
Concept Engineering Fabrication Assembly Service
Next: Industries Served

43. More about Align
•Headquartered in
Decatur, IL since 1964
•Sales offices in Detroit
and St. Louis
•Design & manufacture
everything we sell
•Projects completed with
90% of Fortune 500
•60,000 sq. ft. of
manufacturing space
•3,000 sq. ft. ‘Innovation
Center’ for engineering
•Laser-cutter reduction
used on all designs
•Service and/or refurbish
what we sell

44. Industries Served
• Aerospace
• Agriculture
• Appliance
• Automotive
• Chemical
• Construction
• Locomotive
• Mining
• Nuclear
• Prefabricated Home
• Printing
• Rigging
• Ship Building
• Steel
• Theater and Stadium
Seating
Next: Our Clients
… and Many More

45. Our Clients Include:
Next: Air Bearing Myths

46. European Clients
• Fiat
• CNH
• Caterpillar
• Hitachi
• Komatsu
• General Electric
• Bell/Agusta (BAAC)
• Alcoa
• Daewoo
• Peugeot
• ABB
• Citroen
Silvestrini equipment is found in over 20 countries

47. Recent Awards & Achievements
• 2000 – Awarded Q1 Preferred Quality Award by
Ford Motor Co.
• 2008 – Partnered with GE Transportation to create
world’s first moving assembly line for locomotives
(Erie, Penn.)
• 2009 – Awarded Performance Excellence Award
(Gold Level) by Boeing for excellent supplier
performance
• 2012 – Awarded Recognition in Innovation by Steel
Manufacturers Association (SMA)
Next: Final Questions

48. Thank You
Questions?