Consolidation of three plants, three warehouses, and one distribution center under one roof, including the development and implementation of a new layout design including work processes, and a new operating model.
Together with the client, we developed and executed a six-step program:
STEP 1. Baseline development for production capabilities and demand projections.
STEP 2. Simulation and analysis of projected demand and plant production, current versus future requirements. As well, prepared investment analysis for equipment acquisition.
STEP 3. Workstation Designs for assembly and packaging, considering requirements for equipment, spacing and staffing.
STEP 4. Raw materials and WIP designed two warehouses in support of production planning. The layout designs included new fixed and mobile equipment for space optimization (m2 and m3), as well as the positioning and use of the equiopment for optimal material flow.
STEPS 5 AND 6. Plant design covering an optimum flow of operations from receiving of raw materials, production (placement of equipment) WIP warehousing, assembly stations, and a finished goods distribution center. All designs included a summary of requirements for production, fixed and mobile equipment.
In addition to the six steps, in support of operational performances, we developed reference materials including design specifications, process mapping, execution of the operating model, and for human resources an outline of roles and responsibilities.
For more information about our services, contact our specialized team