MATERIAL HANDLING IMPROVEMENT

PROJECT INCLUDES:

IMEG was hired to improve the material handling method of purchased components from the warehouse to the assembly lines by developing a tugger cart system. The customer manufactures various standard and customized electrical cabinets for the Industrial and IT industries. The mid-west manufacturing facility contains an 8-story automated storage and retrieval system as well as a 3-mile paint line.

THE PROBLEM

No existing raw material delivery system

Overabundance of unneeded material on the assembly line

Disorganization of materials causing delays on the assembly line and extra time spent looking for raw material storage locations

THE PLAN

Verify and update the current AutoCAD plant layout

Evaluate purchased component material data and develop a Plan for Every Part (PFEP)

Study current material flow and material travel paths for all purchased components

Identify assembly line point of use for all lineside purchased materials

Develop proposed AutoCAD plant layouts for reduced travel distances, improved material flow, and optimized material storage

Calculate the required manning for the tugger cart system to meet projected production volumes

Develop a Return on Investment to identify all cost reductions by implementing the tugger cart system

Construct operator work instructions for proper operation of the tugger cart system

Develop an auditing process for lineside racking and purchased part storage to maintain the implemented 5S initiatives and tugger cart system functionality

THE RESULTS

Eliminated line-side material shortages

Improved 5S in the warehouse and at the assembly lines

Reduced required material handling labor by 25%

Reduced non-value add labor at the assembly lines by providing consistent material storage presentation

Reduced non-value add labor in the warehouse by providing organized part kit storage locations