Large Truck Manufacturing Facility Flow Planner Software Results

Leaders in Manufacturing Process Engineering Introduction Project to Document and Calculate Material Flow Compile Material Handling Routing File Generating Material Flow Diagrams Create Flow Results Report & Indirect Labor Determine Material Handling Utilization Levels Evaluate Better Receiving Dock Assignments

Leaders in Manufacturing Process Engineering Routing File Data Collection Product Name – Truck Model Number Part Name –Part Number Percent Flow – Percent of Parts Being Moved to Different Locations From Location Name – Dock Information Method Name – Fork Lift Information Container Name - Pallet Containers per Trip – Number of Containers Moved per Trip Parts per Container – Standard Pack Information To Location Name – Line Location Via Location Name – Drop Zone Information Via Method – Forklift Information Via Containers Per Trip – Number of Containers Moved per Trip

Leaders in Manufacturing Process Engineering Routing File 2300 Routings from Dock to Drop Storage to Line

Leaders in Manufacturing Process Engineering Part Quantity File Assigned Part Quantities to Departments

Leaders in Manufacturing Process Engineering Material Handling Assumptions MH Parameters

Leaders in Manufacturing Process Engineering Layout File AutoCAD Drawing (.dwg) of Facility Layout

Leaders in Manufacturing Process Engineering Straight Line Flow Study Straight – Line Material Flow by Department

Leaders in Manufacturing Process Engineering Aisle Based Material Flows Aisle Based Flows for all MH devices at 100%, 50%, 40% Efficiency

Leaders in Manufacturing Process Engineering Flow Results Material Flow Summary for all Moves (Using Aisle Network) Aisle FlowsTotal Distance (Feet) Total Time (Minutes)Travel Time (Minutes) Total Cost 100% Efficiency11,684, ,619,156.32,655,537.37$20, % Efficiency23,368, ,274,693.75,311,074.73$34, % Efficiency29,210, ,602,462.36,638,843.31$42,235.90

Leaders in Manufacturing Process Engineering Material Handling Device Utilization Material Handling Utilization for all Devices (Using Aisle Network) METHODQUANTITY TRAVEL TIME MINUTES L/UL TIME MINUTES TOTAL TIME MINUTES AVAIL TIME/QTY UTILIZATION FORK-D2038, , , , % FORK-L45, , , , % 100% TOTAL2444, , , , % FORK-D2077, , , , % FORK-L411, , , , % 50% TOTAL2488, , , , % FORK-D2096, , , , % FORK-L414, , , , % 40% TOTAL24110, , , , %

Leaders in Manufacturing Process Engineering Dock Flows Dock 1 to all Drop Storage Zones

Leaders in Manufacturing Process Engineering Dock Flows Dock 2 to all Drop Storage Zones

Leaders in Manufacturing Process Engineering Dock Flows Dock 3 to all Drop Storage Zones

Leaders in Manufacturing Process Engineering Distance Intensity Study Over 100 parts being taken over 500’ more then 10 times per 10 days Example: Part NameFromToFrequencyCalculated Distance 28588R1A '-7" C1A '-8" 25222R1A '-8" C1A '-6" C1A '-6"

Leaders in Manufacturing Process Engineering Summary – Flow Report calculated MH Cost of $34, per 10 Days – MH Utilization Report Indicates Forklift Utilization below 40% – Dock flow study shows many parts could be received at closer docks – Working with IEs to develop Material Flow Database to document further improvements – Working with IEs for tugger analysis and dock capacity studies Tugger Route Generator Dock Capacity Calculator