IMEG was hired by a leading manufacturer of industrial and IT enclosures, racks, and, accessories to develop proper Work in Progress (WIP) levels and material flow for their paint line load and unload areas of the facility.
PROJECT GOAL
Inefficient material staging areas
Additional time and materials spent locating parts and replacing lost material
No defined paint line capacity
flow analysis
THE PLAN
Analyze current raw and painted parts that flow through the paint line by volume and size
Develop WIP quantities for paint load and unload material based on budgeted volumes
Identify paint load station and downstream assembly material usage
Complete storage analysis for all needed materials to determine the location and floor space required
Develop a capacity utilization tool to evaluate the utilization and throughput of the paint line
Create WIP material layouts to improve material identification, presentation, and reduce time required to locate parts
flow analysis
THE RESULTS
Improved 5S and workplace organization
Improved part organization which resulted in reduced time spent looking for parts
Optimized WIP storage quantities
Developed paint utilization tool to assist with proper production and material flow planning
