Programs/Services - Example Projects
Example Projects | Agility Resources | Examples of Industry PartnersOperational Improvements | Product Development & Enhancement
Enterprise Resource Integration
Operational Improvements
Kraft Foods Inc., Allentown, PA, a large and highly complex food production operation, was faced with a challenge from its parent company to either trim costs - without affecting quality and service - or face plant closure. Under these competitive, the ESC was brought in to help increase productivity and reduce process inefficiency. The resulting intensive project consisted of improving product flow, analyzing labor staffing, eliminating capacity bottlenecks, analyzing line flow and maximizing throughput, restructuring warehouse operations, and improving and documenting distribution procedures.
The effort generated significant long-term results for the company, including increased line speed and throughput, implementation of optimum production scheduling that minimizes changeovers and production costs, reduction of holdover and downtime, and identification of over $2,000,000 in cost savings.
DAY-TIMER, Inc., Allentown, PA, made a corporate decision to use advanced digital printing technology as a means to manufacture customizable personal organizer products. The company contacted ESC personnel to analyze and simulate their manufacturing systems and capabilities in advance of implementing the new printing technology and associated finishing operations. After extensive interviewing and data collection, the ESC developed a manufacturing simulation model which helped to identify potential problems, eliminated bottlenecks, and enhanced labor staffing. Concurrently, ESC personnel helped the company to change its entire manufacturing approach to embrace shorter lead times and small lot production. The new lines refined through this process met new production requirements while dovetailing with the final assembly operations. The project enabled Day-Timers to save over $2,000,000 in reduced inventories, improve efficiency by 25%, establish a turn-around time for customized orders at five business days, and reduce cycle time on generic orders from six weeks to five business days.
