PMC was retained by a major automotive OEM to perform analyses of material flow within an integrated stamping and sub-assembly plant. The OEM not only wanted recommendations on proposed bar-coding systems and reallocation of production personnel, they also required a reliable tool with which to evaluate future proposed changes to the system. Throughout the project, PMC’s team utilized a variety of industrial engineering techniques. Recommendations were offered, and a custom fit tool was created. Through use of these instruments, the client’s requirements were met.
The plant studied was one of the largest in the automotive industry, containing 23 press lines and occupying 2.5 million square feet. Key system details included:
The plant was suffering in several areas relating to inefficient material flow:
PMC’s plan was to thoroughly study, analyze, and evaluate infrastructure requirements for better tracking and management of the material handling equipment fleet in the plant facility. This was achieved by utilizing several methods including: continuous and elemental time studies, static simulation modeling using Flow Path Calculator; and dynamic simulation modeling using Witness software.
Upon project completion, PMC’s team delivered:
PMC’s solution offered tremendous savings to the automotive OEM: