PAINT LINE MATERIAL FLOW ANALYSIS

material staging efficiency

SERVICE AREA:

IMEG partnered with a leading manufacturer of industrial and IT enclosures, racks, and accessories to optimize material flow and establish proper Work in Progress (WIP) levels at the paint line load and unload areas. The objective was to eliminate inefficiencies in staging, improve part traceability, and support long-term production planning through data-driven tools.

THE PROBLEM

material flow layout design

THE PLAN

Analyze raw and painted part volumes and dimensions flowing through the paint line
Develop optimal WIP quantities for paint load and unload areas based on forecasted production volumes
Identify material usage points at both the paint load station and downstream assembly areas
Conduct a comprehensive storage analysis to determine appropriate material locations and required floor space
Create a Paint Line Capacity Utilization Tool to track throughput and utilization for better resource management
Develop WIP layout diagrams to streamline material identification, improve staging presentation, and minimize search time

line optimization

THE RESULTS

Improved 5S standards and enhanced workplace organization in the paint line area
Streamlined part organization, significantly reducing time spent searching for components
Optimized WIP storage levels to align with production needs and reduce floor congestion
Developed a custom paint line utilization tool to enable proactive production scheduling and material flow planning