Process Improvement

Case Studies Tags: ,
Process Improvement


Stamping Plant Material Handling for Overseas Part Shipment


Chrysler Corporation


    • 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


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.