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Today, we’re taking a closer look at a specialized custom timer unit that’s headed to a Walmart Distribution Center. This product was designed to help the logistics team manage how long each dock door is occupied by a truck—and to ensure that idling times are kept under control.

This system acts as a real-time monitor for truck idle times. The key goal? To police how long a truck occupies a door, helping to reduce inefficiencies and avoid unnecessary congestion at the dock. Here’s how it works and what sets it apart.

Core Functionality

The timer is an up-timer, which means it starts counting from zero once triggered. The user can set a threshold time—say, 1 minute or up to 99 hours and 59 minutes—using BCD rotary switches conveniently located at the top of the enclosure.

When a truck backs into a bay, a magnetic receiver sensor on the dock door aligns with a base sensor embedded in the floor. This contact resets the timer to zero. The moment the connection is broken (i.e., when the truck leaves or the door is no longer in position), the timer begins counting up in hours and minutes.

Visual Indicators

Even though the display doesn’t show seconds, the flashing colons between the digits act as an indicator that the unit is actively counting. This subtle but effective visual cue keeps users informed without cluttering the screen.

Once the threshold is reached—for example, after 1 minute of idle time—the Andon light activates, turning red. This clear alert signals staff that the time limit has been exceeded, helping them take immediate action if needed. And notably, the timer continues to count even after reaching the threshold, all the way up to 99 hours and 59 minutes if needed.

Adjusting Threshold Time

To adjust the countdown target, users simply insert a flathead screwdriver into the BCD rotary switches. Each turn updates the threshold value, and the display shows the new setting in real time. This feature ensures quick and accurate configuration without guesswork. A small illuminated dot appears on the left side of the screen to confirm you’re in the setting mode.

Hardware Overview

Let’s look at the rugged construction and components of this unit:

• Enclosure: Black powder-coated aluminum for durability and corrosion resistance
• Display: Four-digit, 4-inch high LED numbers
• Visibility: Easily viewable from up to 200 feet away
• Counting Range: Up to 99 hours and 59 minutes
• Sensor: Heavy-duty magnetic proximity sensor, epoxy-encased for long-term resilience
• Visual Alert: Bright red Andon light triggered once threshold time is reached

Summary

The DC-40T-UP-BCD-ANDON-HORN-WR is a purpose-built solution for industrial operations like those at Walmart DCs. It helps keep dock activity moving efficiently and holds idle time accountable with clear visual cues and easy configuration. This USA-made unit not only improves time management but also reduces operational lag, one truck at a time.

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