IMEG was asked to help improve production efficiency on finished product packaging lines for a furniture manufacturer.
THE PROBLEM
High labor costs
Trapped labor
High equipment & product change over times
Underutilized labor
packaging process, reduce trapped labor
THE PLAN
Conduct Time Studies with performance ratings to determine the current station workload
Perform Work Sampling Studies to identify process inefficiencies such as re-arranging parts, equipment downtime, and quality issues
Evaluate the material delivery and the presentation at the packaging lines to reduce change over time, minimize non-value-added work, and reduce travel distances throughout the facility
Create Work Balance Charts to level load work across all stations to reduce trapped labor, reduce bottlenecks, and improve product throughput
Develop AutoCAD Line Layouts & Plant Layout Analysis to identify the optimal packaging line and plant layouts
reduce trapped labor
station workload
THE RESULTS
reduce trapped labor
Improved production throughput by 23%
Reduced trapped labor
Streamlined production processes
Reduced product change over time
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