PLANT LAYOUT
We STREAMLINE your Plant Layout
Common Tasks:
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Redesign plant layout to improve material flows
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Conceptual design of production and warehouse areas for green- and brownfield plant constructions or expansions
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Development and mapping of future processes to assure lean material flows throughout the plant and warehouse
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Removal (e.g. outsourcing) of support processes/functionalities to gain space for core processes
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Operational feasibility and functionality assessment of architectural plans for plant constructions or expansions
Methods and Tools:
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Material Flow Assessment
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Value Stream Design
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Workload Study
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Feasibility and Functionality Study
Reference Industries:
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Pharmaceuticals
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Automotive
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Utility Vehicles
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Parts and Components
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Manufacturing
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Building materials
Ø Project Duration:
Ø Project Payback:
8 - 12 weeks
4 - 6 months
bottom line optimization 15 - 25%
Industry:
Company Size:
Project Location:
Global Automotive Supplier
8,000+
Mexico
Problem Statement:
Our customer is a leading supplier to the Automotive industry. Due to substantial growth over the past years, one of their plants in Mexico has reached its maximum production capacity. A large OEM wants to place additional, long-term business with this plant, but without the ability to increase the production capacity, the order has to be rejected.
STREAMLINERS' Approach and Solution
Meeting:
High level understanding of all core production processes and the used machines; plant footprint with all operational/functional areas
Deep Dive:
Detailed map of all operational/functional areas in the plant; in depth analysis of area consumption per functionality and conceptual design of future plant layout
Hypothesis:
The deep dive revealed that 18% of the plant's footprint are used as storage areas for raw materials, WIP and finished goods. If all storage areas could be moved to an external warehouse, the freed up space could be used for production and increase the production capacity by 30%. The costs for external storage and material handling would be marginal in relation to the profit generated by the increased revenue.
Project:
2 consultants
12 weeks
Deliverables:
Detail design of future plant layout developed and approved
All future core processes aligned and mapped
Market analysis for rental warehouses as well as for 3PL providers performed
Self-managed external warehouse vs. 3PL simulated and evaluated
Implementation road map external warehouse developed
Bottom Line Impact:
Increase production capacity by 24%
External logistics infrastructure only 3% of additional revenue
Opportunity Capacity Increase
Fees vs. Bottom Line Impact
