Site Planning & Facility Layout – Chain Link Fence Manufacturer

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PROJECT

Site Planning & Facility Layout

CUSTOMER

Chain Link Fence Manufacturer

OVERVIEW

Our Process Optimization Team was engaged as a partner and extension to our client’s team to identify process issues and improve material flow of site and entire facility to reduce the headcount, improve material handling efficiencies as well as improve site safety. The team optimized the facility layout to support business growth for the next 5 years with additional production and storage capacity.

PROJECT WINS

  • Optimized facility layout and flow to increase capacity and meet future sales growth.
  • Redesigned the internal warehouse to optimize storage space and increase pallet storage capacity by 50%.
  • Redesigned the 200K+ Sq. Ft. yard to improve storage and material flow, reduce congestion as well as increase safety.
  • Improved picking and material handling efficiencies.
  • Identified aged (potentially obsolete) materials.
  • Worked with the IT system providers to ensure the system supported the new material flow processes.

BOTTOM-LINE RESULTS:

  • 50% improvement on pallet storage
  • 30% improvement on manufacturing capacity
  • One way traffic flow to improve safety and reduce truck turnaround time
  • 20% aged (potentially obsolete) inventory identified
  • 15% reduction on picking time

Manufacturing Process and Material Flow – Aerospace and Mass Transit

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PROJECT

Manufacturing Process and Material Flow

CUSTOMER

Aerospace and Mass Transit Component Manufacturer

OVERVIEW

Our Process Optimization Team was engaged as a partner and extension to the customer team to identify and improve efficiencies through facility consolidations, manufacturing process and material flow improvements.

GOALS AND OBJECTIVES

  • Redesigned production layouts to optimize space utilization.
  • Perform dock analysis to determine optimal receiving dock locations.
  • Instrumental in centralization of production and consolidation of three facilities.
  • Incorporated sub-assembly cells for insourced work.
  • Optimized production using lean principles to increase throughput.

BOTTOM-LINE RESULTS:

  • 41% efficiency gain in material flow
  • 43% improvement in production
  • 16% increase in assembly throughput