Material Movement Study – Blanking & Stamping

January 31, 2024

Material Movement Study – Blanking & Stamping


mbawankar |

AUTOMOTIVE INDUSTRYMaterial Movement Study

Material Movement Study - Blanking & Stamping

Key Points

  • Greenfield facility: MHE requirements
    & congestion analysis

Client's Challenge

  • Ensure blanking & stamping does not constrain production at body shop
  • Optimize MHE requirements
  • Analyze impact of crane movement on changeover time &

PMI's Approach

  • Analysis of Data and Verification of Baseline Model
  • Understand impact of:
    1. Number of forklifts
    2. Die Changeover time at Blanking Line; on throughput
  • Capture impact of material movement congestion

Findings & Recommendation

  • Drops in production due to congestion of forklifts at
    Stamping Storage area
  • Under-utilized forklifts at end of Blanking line
  • Reduced congestion by proposing that forklifts carry 2
  • 30% reduction in MHE requirment by eliminating underutilized forklifts
  • Identified 30 minutes as maximum allowable changeover
    time at Blanking

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