Process Improvement

PROJECT

Stamping Plant Material Handling for Overseas Part Shipment

CUSTOMER

Chrysler Corporation

Objectives

• • Develop methods to allow direct shipment of stamped parts to an overseas plant
  • Develop layout changes needed for implementation
  • Determine production and material handling labor requirements
  • Develop implementation approach and schedule
  • Simulate material handling operations to verify recommended methods and layout changes

Description

Current operations required a U.S. stamping plant to send all parts for overseas shipment to a third party to “repack” parts for shipment. The project studied current operations, identified packaging, method and operational improvements to allow direct overseas shipment of required parts.

“Bottom Line” Results

• Created a detailed plant layout with optimized material flows.
• Verified recommendations with material handling simulation.
• Eliminated “repack” operations saving $1 million per year.
• Developed detailed implementation plan and schedule.