Volume and variety: Universal goals in today’s distribution and material handling.
As this function has evolved from back-office, operational fulfillment to an extension of the physical line, it has also become a strategic differentiator in the delivery and cost of goods sold.
Our technical understanding of the interconnection between inventory management, production planning, traffic flow and existing/new product and packaging sales creates strategic advantage for customers.
Our differentiating point is in developing designs to handle the volume and variety of the current and future product mix in the most cost effective manner. We help clients react to quick changes in production schedules; product matrix; inventory management; and logistics decisions.
Through comprehensive design and management, we’ll account for your inventory space requirements, traffic flow, flexibility, automation opportunities, and special requirements based on your product portfolio. We also evaluate the whole life cycle of materials and systems to provide efficiency and sustainability throughout your operations.
System Modeling & Capacity Analysis
Simulation and emulation are computer models that mimic the real system, with or without the use of a PLC, to provide insight on system operations and performance, and to verify controls strategies or the actual line controls. Capacity Analysis is a spreadsheet-based tool that includes three types of analysis: Palletizer (Unitizing), Trunkline, and Merge Analysis. It helps identify the capability of the system and current or future constraints in the system. Output of the analysis is used to create options for designing the system.
Shipping/Receiving Dock Requirements
When determining growth or capability of a warehouse or distribution center, the dock doors are often times a bottleneck for getting the materials in and out in a streamlined manner. Our tools utilize customer-specific input to help them determine the minimum number of dock doors required and traffic glow to support the plant’s planned throughput.
Full Goods Inventory
Depending on the process each customer uses for shipping their full goods, analysis and calculations are used to determine the optimal quantity of stored on-hand full goods as well as required shipping practices to the end user or distribution center. Based on available storage area, product environment requirements, and turn time, we provide our clients with the plans and minimum space required for storing full goods.
Raw Material Handling/Storage
To have a smoothly run, optimized process, the raw goods must be received, stored, and ultimately brought to the manufacturing system for consumption. At times, certain products must be handled with specific storage requirements in mind – whether it is product that is rarely used, contains allergens, is flammable, or simply requires special consideration. Our clients use our raw material warehouse designs, plans and layouts to ensure that the material handling and storage requirements are at a minimum.
Material Handling System Designs
Material Handling System designs are created using a formal process. The first step of the process is to gain stakeholder alignment on the production design basis of the system. A capacity analysis is performed based on this design basis to determine the major equipment required to achieve the production requirements. Flow diagrams are developed to simply illustrate possible routing of material from the end of the production line to the finished unit pick off point. The next step is the development of the 2-dimensional or 3-dimensional system layout of the actual equipment within the facility. Further refinement of the system can be achieved through simulation. The final material handling system design will incorporate good material handling practices, innovative concepts where appropriate, and special consideration of options that will enable the system to be efficiently operated and maintained while supporting the overall objectives of the business.
Traffic Flow Analysis
Moving products within a warehouse can prove to be some of the most time consuming portions of the manufacturing process. We have provided our clients with ideal layouts that have drastically reduced the distances of required driving, thus minimizing the driving distance. This results in a reducing the risks associated with significant movement within the warehouse as well as the time required for product movement.
GMPs/Sanitation Requirements
We understand the need for Good Manufacturing Practices, as well as sanitation methods and procedures critical for many operations. We understand dusty environments, as well as strict food and dairy sanitation requirements and pharmaceutical requirements, including cleaning procedures for CIP, COP, and SIP.
