Greenfield Facility – Throughput Validation and Improvement
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STEEL INDUSTRYGreenfieldThroughput Validation
Greenfield Facility - Throughput Validation and Improvement
Key Points
- Batch type production - 14 Product Types
- Impact of Product Mix on system throughput
- Buffer sensitivity analysis
Client's Challenge
- 14 Product types with different foundry flow and product-dependent cycle
time made it difficult to calculate the system's throughput - Equipment Utilization was highly dependent on Product Mix
- Batch size of a product family - Different across the process flow
- With all the above variations, predicting the required buffer capacities
PMI's Approach
- Data analysis, 3D model building, verification & validation
- Throughput improvement carried out by analysis of product mix
- Sensitivity Analysis carried out on buffer capacity
- The throughput Improvement Roadmap was built to meet the expected demand
- Sensitivity Analysis also carried out on buffer capacity for expected demand
Findings & Recommendation
- The facility was unable to meet the target throughput
- Throughput showed strong dependence on Product Mix
- With the current setup, max. system throughput was validated to be 18% less than expected
- The number of resources required to satisfy expected demand was calculated
- Required buffer capacities around the facility were suggested
- The average lead time was indicated
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