Greenfield Facility – Throughput Validation and Improvement

January 31, 2024

Greenfield Facility – Throughput Validation and Improvement


mbawankar |

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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