Project Description
A vitamin and supplement manufacturer located on the East Coast contacted Design Systems, Inc. with the intent of constructing a new building due to space constraints. Following a no-risk assessment conducted by our cross-functional team, Design Systems, Inc. was able to identify opportunities in order to resolve perceived space constraints and improve core processes.
Client Objectives
Conduct assessment to understand overall supply chain flow within facilities.
Evaluate picking / shipping area, developing Best in Class approaches to process and storage.
Increase productivity, throughput and accuracy through process improvement and implementation of automation solutions.
Assist in the creation of a scheduling department and procedures that allow for more robust planning and input into a disciplined Material Requirements Planning process.
Provide detailed list of excess material for disposition.
Make high level organizational structure recommendations.
Project Outcomes
Resolved space constraints without requiring purchase of a new building
Space, productivity, safety and labor savings of $700,000
75% improvement in replenishment productivity
190% improvement in throughput while reducing 3 operating lines (from 8 lines to 5 lines)
Installation of 2 VLM’s to store 70% of pick volume with 60% space savings
Identified and eliminated organizational concerns to improve overall morale and productivity