Material Flow Optimization Webinar & Case Study Example A major project was performed at a stamping plant to identify opportunities for efficiency improvements. Various indirect labor assignments were evaluated including forklift
Material Flow Optimization Webinar & Case Study Example
A major project was performed at a stamping plant to identify opportunities for efficiency improvements. Various indirect labor assignments were evaluated including forklift drivers, tugger drivers, crane operators, die setters, and stock chasers. Also, various data collection and analysis techniques were used in the project. The study generated recommendations for reallocation of indirect labor and material flow improvements for current and future state operations. The recommendations provided input to management about resource improvement proposals for local Union contract negotiations and resulted in several million dollars in potential savings for the client.
Facility Layout and Material flow Optimization is the evaluation of multiple layout scenarios to design the optimum layout that reduces material handling costs, improves throughput, and minimizes space requirements.
Use of CAD in MFA and Layout optimization
Accurate 2D and 3D CAD data is the essential starting point in any analysis and improvement efforts for material flow or layout design. Being a multi-faceted company, PMC leverages its digital engineering expertise to help create existing plant models for our clients. To assist with this task, we created an extensive asset library consisting of all major MH, tooling, and equipment designs to suit all industry needs. With that said PMC also has the added ability and experience in designing custom/task specific material handling solutions for unique situations. This added level of detail helps in more accurate visualizations of the plant as a whole and makes it easy to tackle inefficiencies.
Ergonomic Material Handling Equipment
PMC’s expertise in evaluation of ergonomically standard material handling equipment and stations based on Anthropometric Measurements gives a different dimension in designing the line side equipment and delivery of product. This approach of Material Handling is ergonomically operator centric as well as efficient for the overall Material Handling design. With a combination of CAD designs and Ergonomic simulations, the following estimates can be made which are vital for operator wellbeing and process efficiency.
- Optimize pick upic heights
- Optimum reach
- Optimum workstation/line side equipment heights and reaches
- Permissible Load Limit
- Worker Load Repetition
Static material flow analysis
It can be used in sync with a PFEP which is part of data collection/creation phase. It is a perfect precursor to a complete discrete-event simulation run as it requires less data, so it is faster and provides valuable insights for further analysis and choose ideal scenarios. Proplanner provides the following outputs, among others:
- Aisle congestions
- Point to point material flow
- Euclidean Distance
- Spaghetti diagrams
- Dock Utilization
Dynamic Simulation for Material Flow
PMCs expertise in discrete and continuous event simulation in a wide variety of simulation packages has benefited multiple clients over 30 years. Especially in the field of material handling, our dynamic simulation techniques allowed the client to efficiently plan for production ramping, design and optimize material handling routes, estimate accurate line side equipment, estimate Finished Goods inventory, optimize layout, optimize dock operations and warehouse footprints etc.
PMC Material Flow Case Study (Material Flow Study Reveals Over $4M Potential Annual Savings for Automotive OEM): https://bit.ly/2TBl95H
Other PMC Services:
Laser Scanning & 3D Modeling: https://bit.ly/3iY6LQg
Facility Layout & Material Flow Optimization: https://bit.ly/2SgLZQ1
Manufacturing Productivity: https://bit.ly/3ioGmd8
Program Management: https://bit.ly/2HDTA9d
Quality Assessment & Roadmap: https://bit.ly/3m4339L
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