Situation: Management not able to readily identify which pieces of equipment had the highest repair costs. No record of employee skill set for operating various types of equipment. The PM software for equipment was not current or utilized to its fullest capability. No full time maintenance … [Read more...]

Situation: All items stored in random locations. No forward pick zone, therefore, the pick and storage locations of an item are the same locations. Items must be picked with expensive lift equipment. Travel distances and time to pick an order is excessive. Dock operations become a … [Read more...]

Situation: All items stored in locations without regard to velocity and typical pick quantity No forward pick zone. The pick and storage locations of an item are the same locations. Items must be picked with expensive lift equipment. Travel distances and time to pick an order is … [Read more...]

Situation Receiving all products at the main dock doors and pre-labeling/storing boxes. Critical Issue: Must travel approximately 312 feet to unload and store product. Traffic interference with outbound completed product flowing in the opposite direction frequently … [Read more...]

Situation: 27 order pickers on 3 shifts riding through the Distribution Center on counter balanced lift trucks and picking approximately 50-55 orders per day. Over 430 skus located by product number and some randomly throughout the Distribution Center. Travel time was approximately 27% of … [Read more...]

Situation: 65 order pickers walking through the Distribution Center pulling handcarts and picking approximately 2000 orders per day. Over 20,000 skus located by family and some randomly throughout the Distribution Center. Travel time was approximately 50% of the Order Pickers time. Orders … [Read more...]

Situation: Backlog of several customer orders, no direct labor standards, no capacity planning, very ineffective production scheduling, significant unfavorable direct labor variances and poor customer service. Critical Issue: The direct labor costs per unit completed were excessive and the … [Read more...]

SITUATION: Production batching operations not able to meet customer demands. CRITICAL ISSUE: Production management and Engineering looked long and hard at increasing the amount of equipment needed to do more batching without evaluating the available capacity of support resources such as … [Read more...]

SITUATION: The current manufacturing facility was very over crowded with production operations.  Material handling is excessive and causes significant delays in production throughput. CRITICAL ISSUE: Production facility cannot meet throughput levels and customer service … [Read more...]

Situation: Work area cluttered, messy and very disorganized. Raw materials used in the dry mix batching operation scattered throughout the warehouse. Packaging supplies scattered throughout the warehouse. Tools used for making changeovers and adjustments some were missing and others not … [Read more...]