Experts in material handling and conveyors –
helping our clients with efficient, effective automation and conveyor solutions

Lear Corporation

March 31, 2014


Lear is one of the world’s leading suppliers of automotive seating and electrical distribution systems. The company’s products are designed, engineered and manufactured by approximately 122,000 employees located in 36 countries. The new UK site in Coventry was opened in 2013 to support Jaguar Land Rover’s F-type launch.

LB Foster Materials Handling has completed two major contracts at the Lear Corporation’s Coventry facility. One contract was for a production line carousel conveyor and the second, for a dispatch conveyor system to store completed car seats in sequence on a cassette.

The rectangular carousel we manufactured and installed is an indexing conveyor using accumulating chain and powered rollers. It was constructed so the operatives working on the carousel can produce 40 car sets of seats per hour. To save energy, the conveyor shuts down between ‘takt’ times.

Once the seats are finished they are placed on a delivery pallet. The pallets are then loaded onto the new dispatch conveyor system. This consists of a series of three, two tier conveyors which house up to 36 car sets in sequence on a cassette.

When the delivery lorry arrives at the dock, the seats are automatically transferred by conveyor out of the building straight onto conveyors in the back of the lorry. They will be delivered, still in sequence, to the automotive manufacturer.

Gary Bale, managing director of LB Foster Materials Handling said, “We are delighted that Lear selected our company to carry out these two engineering contracts for its Coventry site.

“The successful completion of the projects marks a great start to our business relationship with one of the world’s largest automotive suppliers. It also underlines our ability to integrate bespoke systems into complex manufacturing processes.”

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