Client Project

Band Winder: 66% Labor Reduction

Six-month turnkey build automated manual "scissors and motor" process, reducing workforce from 12 operators to 4

66%

Labor Reduction

From 12 to 4 operators

Units Built

Turnkey system

6 Months

Build Timeline

Concept to commissioning

12→4

Operators Reduced

Across 3 shifts

The Challenge

Performance Health was manually winding exercise bands from 1,000-yard spools into shorter, customer-ready rolls. This labor-intensive process required a massive workforce:

12 operators total (3 shifts of 4 operators each)
Manual everything: Loading spools, cutting with scissors, boxing, and labeling
Inconsistent quality: Manual cutting led to variations
Unscalable: Growing demand couldn't be met without hiring more staff

The client provided detailed financial data showing the true cost of this manual operation, making the ROI case clear for automation.

The Solution

Visionary Automated Solutions designed and built a complete, turnkey automation system over a 6-month engagement. The project included:

Automated Winding

Precision motorized system winds bands to exact specifications every time, eliminating manual inconsistency.

Automated Cutting

Replaced manual scissors with automated cutting system for consistent, repeatable results.

Automated Boxing

Machine places finished rolls directly into boxes, reducing handling and speeding production.

Automated Labeling

Labels applied automatically to boxes for immediate shipping readiness.

We managed the entire project from initial concept and design through fabrication, assembly, programming, and on-site commissioning at the client's Ohio facility.