MATERIAL FLOW
We STREAMLINE your Material Flow
Common Tasks:
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Redesign of material flows to reduce waiting, motion and transportation waste
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Develop new plant layout, fitted to actual (new) process and material flows
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Implement conveying technology to speed up material flows
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Align material flows and production/assembly tact to avoid excess work in progress (WIP)
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Incorporate pull systems (Kanban) to increase flow
Methods and Tools:
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Material Flow Analysis
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Process Mapping/VSM
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Lean Assessment
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Waste Walk
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Continuous Process
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Kanban
Reference Industries:
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Manufacturing
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Automotive
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Engineering
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Parts and Components
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Food
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Building Materials
Ø Project Duration:
Ø Project Payback:
6 - 10 weeks
3 - 6 months
bottom line optimization 15 - 25%
Industry:
Company Size:
Project Location:
Global Pharmaceuticals Manufacturer
30,000+
United States
Problem Statement:
Due to increased market demand, our client was forced to rapidly improve the production output at one of their US plants in order to avoid stock-outs and customer complaints. The client's operations executive team had identified the poor material flows at that facility as a main constraint on their path for growth. If the plant would not radically improve their internal material flows, the required production output to meet customer demand would for sure be missed.
STREAMLINERS' Approach and Solution
Meeting:
Definition of problem statement and scope
Deep Dive:
Understand current material flows, bottlenecks and process constraints in detail to reveal optimization potentials and to draft alternative material flow scenarios
Hypothesis:
Design and implement optimized material flows to drastically reduce required storage capacity, footprint and to significantly improve output performance
Project:
1 consultant
8 weeks
Deliverables:
Optimized material flows implemented
Required storage capacity reduced by 25%
Output performance improved by 13% due to redesigned conveyor system
Outbound freight reduced by 23% due to optimized handling units
Bottom Line Impact:
Output performance improvement 13%
Annual freight savings >$0.8 M
Waste Analysis
Fees vs. Bottom Line Impact
