IMEG was hired by an industry leading manufacturer of pumps to perform capacity utilization analyses on a 17,000 sq ft assembly line consisting of multiple different stages.
THE PROBLEM
No consolidated location for Parts Per Hour (PPH) information and demand volumes
Unclear utilization for each stage of the assembly line
Bottlenecks of the process not identified previously
Part routings from assembly to quality test not defined
No compatibility matrix for WIP in quality test
THE PLAN
Gather all necessary information including PPH, demand from the previous year, expected uptime, working hours per shift, and number of shifts
Perform a capacity utilization analysis on assembly, quality, configuration, paint, and packaging
Provide recommendations on the most optimal number of operators and pieces of equipment
Create a compatibility matrix to complete further analysis
compatibility matrix
THE RESULTS
Calculated utilization percentages for each stage in the assembly line
Interpreted the results into equipment and manning requirements as well as possible scheduling options
Provided the customer with a comprehensive analysis including primary and secondary routings for scheduling based on assembly-quality compatibility matrix
