Customer Profile: A leading manufacturer of furniture products and furniture components
Problem: The company has a large spread-out facility and during the organic growth of the organization, new machines were installed without detailed planning, which led to an inefficient manufacturing process. There was a lot of manual effort due to material movement and delays in execution of orders which required a complete factory re-planning exercise and review.
Solution: We engaged with the client to go deep into the physical layout of the plant. A Value Stream Map was created to identify the flow of material during the order execution and this flow of material was mapped to how the machines needed to be placed in order to reduce the transportation and waiting time. Once this was achieved, an optimum order execution approach and material movement approach was implemented.
Benefit: This approach greatly released a lot of space in the organization shop floor for future growth. The order execution speed increased drastically. Manpower deployed for order executions was considerably reduced. The client was extremely happy with the result of this exercise.
Increasing Factory Throughput