The Challenge

Vitamin and Supplement Manufacturer

Our client is a vitamin and supplement manufacturer located on the East Coast. They initially contacted Design Systems with intent of constructing a new building due to space constraints.  Following a no risk assessment conducted by our cross-functional team, DSI was able to identify opportunities in order to resolve perceived space constraints and improve core processes.

Several challenges were identified after conducting an overall assessment of the supply chain flow within our clients facilities.

The Solution

To solve these challenges – the project team developed the following objectives with our client:

  • Evaluate picking/shipping area, developing best in class approaches to process and storage
  • Increase productivity, throughput, and accuracy through process improvements and implementation of automated solutions
  • Assist in the creation of a scheduling department and procedures that allow for a more robust planning and input into a disciplined Material Requirements Planning (MRP) process
  • Make high level organizational structure recommendations
The DSI Difference

DSI listened to our client’s challenges and goals and identified root causes of the gaps in their system. By taking this project approach, DSI removed the need for our client to construct a new facility – saving millions.

By implementing the solutions in their current facility, our client witnessed the following:

  • Space, productivity, safety, and labor savings of $700,000
  • 75% improvement in replenishment productivity
  • 190% improvement in throughput while reducing 3 operating lines (from 8 lines to 5 lines)
  • Installation of 2 VLM’s to store 70% of pick volume with 60% space savings
  • Identification and elimination of organizational concerns which improved morale and productivity
  • Manufacturing & Industrial
  • Warehousing & Distribution
  • Consulting
  • Engineering
  • Project Management
  • Supply Chain
  • Health Care

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