A manufacturer of large custom industrial equipment hired IMEG to determine how they could utilize cellular manufacturing to increase their operational efficiency in their existing 110,000 sq ft facility.
THE PROBLEM
Need for 5S and workplace organization for tools, materials, and equipment
10.5 hours of putting away parts that were picked for each job
Material transportation by overhead cranes and forklifts
Missing tools that accounted for 3.5 hours of delays per job
Lack of organization resulting in 2 hours of moving large parts via overhead crane
60% process efficiency
Outdated labor standards
Excessive part travel distance
Excessive operator walk distance
THE PLAN
Conducted Time Studies with performance ratings to establish current rates
Conducted Delay Studies to identify processing delays
Capacity Utilization Model created to identify assembly capacity
Created manufacturing layout designs in AutoCAD
THE RESULTS
Identified annual savings of $180,000
Reduced part travel distance by 1933 feet (21%)
Reduced operator walk distance by 12,855 feet (29%)
Reduced delays by 50%
Identified optimal raw material levels at the point of use
Identified tools needed to reduce operator walk distance
