Manufacturing Process and Material Flow

Master Planning

Large Consumer Goods Manufacturer

Overview

Client was seeking to develop a Master Plan for their facility to capture duplication of current state processing capacity, right size storage, and optimize processes.

Project Achievements

1. Right sized and developed warehouse expansion design that adheres to new automated equipment requirements resulting

2. Identified and validated automation opportunities that achieved a 32% reduction in labor compared to current state

3. Streamlined material flow for existing facility and future expansion plans

4. Designed optimized yard and dock areas that alleviated fork truck and trailer congestion

Bottom-line Results

$1.68M ANNUAL LABOR REDUCTION

Through application of lean manufacturing principles, Design Systems, Inc. identified bottlenecks and optimized processes for material flow resulting in 18% labor reduction.

$3.03M LABOR REDUCTION DUE TO AUTOMATION

Design Systems, Inc. identified opportunities where manual processes could be automated throughout the facility. Partnered with vendors to validate the estimated cost savings amounting to 32% annual labor reduction.

$20M AVOIDANCE IN BUILDING EXPANSION

Helped client right size their expansion plans. Original estimate was 640k sq. ft., reduced to 560k sq. ft. resulting in $20M cost avoidance.