Michigan Foam Products (MFP) is a foam manufacturer located in Grand Rapids that specializes in making Expanded Polystyrene (EPS) foam. This project aimed to make the process of loading and transporting large, 16 foot tall, foam blocks in and out of storage, easier for operators as well as making the task manageable for more employees. This being because the current process only allows a third of the employees to complete it and has resulted in injuries in the past. The foam blocks range in weight from 168 to 650 pounds and are stored in rows of twelve. The blocks were to remain accessible in the existing row configuration at MFP and follow the idea of first-in-first-out (FIFO) processing. MFP also wanted to implement an inventory system that would allow an employee to search for a block by density and/or customer code. The system will assist operators in locating the blocks based on the search criteria and show a real-time map of inventory on a large display, shortening the amount of search time for each job's material. In addition to searching, the system will also recommend a block placement for storage based on customer code and density, to ensure FIFO processing.

Technical expertise, project knowledge, and equipment to design and fabricate every shape and size of expanded polystyrene (EPS) block molds.