Many industrial engineering tools are available for material flow design. Value stream mapping is one tool used for benchmarking and identifying potential process improvement opportunities.
Productivity Solutions ability to implement and teach Lean Manufacturing practices, Just-In-Time (JIT) replenishment systems, reduce process variances and other tools enables us to save you money.
Material Flow Design Capabilities
- Lean Manufacturing Techniques
- Just-In-Time (JIT) Scheduling
- Takt Time / Line Balancing Techniques
- Equipment Justification Calculations
- Capacity Modeling using Spreadsheet Models
- Digital Simulation Modeling
Architectural Millwork and Installation Company
Builds and installs architectural millwork to high end clients.
- Reduced Rework 30% in 3 months by implementing a tracking and feedback process.
- Created Indirect and Direct labor reports to track and improve key evaluation matrices.
- Reduced processing time 6% by implementing a kitting material handling system.
Liquid Crystal Display Glass (LCD) Fabrication Company
Flat screen display glass melting and finishing operations.
- Performed material handling calculations and storage requirements for two multimillion-dollar expansions.
- Identified capital cost reductions of $25 million and annual operating cost reductions of $750,000.
- Created equipment and lift truck capacity models to assist expansion decisions.
- Created a digital simulation model with ProModel® software of a new fabrication line to identify equipment MTBF, MTTR requirements and help identify bottleneck operations.
- Created a worldwide manufacturing capacity model to determine manufacturing constraints for different market demands.
Pet Food Manufacturer
Mixes, blends, extrudes, dries and bags several flavors of dog food.
- Designed new bagging operations and equipment requirements to eliminate the need for $6 million of work-in-process silos and conveyors.
- Performed capacity and scheduling calculations using digital simulation and ExcelÒ software.
- Identified proper buffer storage queue sizes for 5 automated bagging and palletizing lines.
Projection TV Lens Manufacturer
Extrudes, polishes, assembles, tests and packages several million projection TV lens assemblies annually.
- Performed a complete material workflow study with a 60,000-sq. ft. warehouse layout design to minimize floor space requirements, material handling costs and inventory carrying costs.
- Reduced annual inventory carrying costs $140,000 and annual operating costs $90,000 by performing a comprehensive workflow study.
- Provided spreadsheet models for re-calculating reorder-point levels and inventory turns to minimize inventory-carrying costs of different product forecasts.
- Generated six (6) equipment cost justifications that supported recommendations.
Compressed Gas Equipment Manufacturer
Machines, assembles, tests and packages medical, welding, manifold and compressed gas fitting assemblies.
- Implemented leveled scheduling with new assembly cell layouts for continuous flow processing utilizing Kanban cards to improve production efficiency 15%.
- Reduced Work-In-Process (WIP) inventory 10% for several product lines.
- Installed bar coding for finished product inventory tracking.