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
Right sized and developed warehouse expansion design that adheres to new automated equipment requirements resulting
Identified and validated automation opportunities that achieved a 32% reduction in labor compared to current state
Streamlined material flow for existing facility and future expansion plans
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, DSI identified bottlenecks and optimized processes for material flow resulting in 18% labor reduction.
$3.03M LABOR REDUCTION DUE TO AUTOMATION
DSI 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.