%20-%2011_2_2021%20(v1).jpg)
Project Data
Client: Fortune 500 Global Corporation specializing in Robotics, Power, Electrical Equipment & Automation Technology
Location: New Jersey, USA
Timeframe: 2 Months
Key Project Factors: Client had invested in a new MVR Surge Arrester manufacturing line and was looking to optimize the process and layout of the facility to support efficient operations. Both manufacturing tooling layout and flow had to be designed as well as the store supporting the MVR area with raw materials. Optimized processes were needed to ensure operational performance in this area resulted in a positive return-on-investment for the client.
The Challenge
Client needed a new layout and process for their MVR Assembly operation and the associated MVR Store that supplied the manufacturing operation. The major components of the MVR assembly operation needed to be installed with sub assembly and assembly workstations and product flow components needed to be designed and implemented. A material and parts storage area was also needing to be designed and installed to hold product and materials used to satisfy the MVR Assembly Workstations, subsequently being replenished from the client's remote warehouses.
The Approach
Optimized manufacturing assembly designs and alternative options that improved throughput, productivity and flow needed to be considered to meet the client's needs. Given past challenges with operational performance and exception handling (shortages/outages of materials) in other manufacturing areas of the client's facility, material supply and transfer to the MVR operation needed to be optimized to minimize assembly delays and improve operational efficiency.
The Results
Initial plans for the MVR Assembly area were reviewed, redesigned and optimized evaluating people, process, system and MHE improvements. The MVR Store operations were designed to incorporate "quick-win" layout and process changes and completed prior to the MVR Assembly implementation to support go-live of manufacturing operations. Layout optimization of both the MVR Assembly and MVR Store operations resulted in a net reduction in associated labor cost of 50%, allowing ROI to be achieved in a reduced timeframe for the client.
