Pack Line Process Improvement Project-Cart-VideoWall

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Identified Opportunities to

Increase Productivity

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• Updated designs for packaging and cell

layouts for high labor content products

• SR560M and other carts and Stands

• DS-VW765-LAND – Video Wall

• Dedicated cells to run shop orders with

optimal crew sizes

Redesigned Layout for Carts & Stands

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Start of the Line: 1 Piece Carton

Placed on Conveyor Components packed at tables

Staples replace tape

End of the Line: 1 Piece Carton End of the Line: Pallet located next to aisle for easy access by forklift

Projected Cost SavingsRedesigned Packaging and Layout for Carts

Before Improvements:

25 units/hour with a crew size of 7 people

EAU = 7,136 units/year – 2,000 labor hours

After Improvements:

28 units/hour with a crew size of 6 people

EAU = 7,136 units/year – 1,529 labor hours

Total Labor Hours Saved = 471 hours

Labor Rate = $42.14/hour

Estimated Total Annual Savings = $ 19,8504

Redesigned Packaging for Video Walls

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Carton is too deep –

requires extra filler paper

Inserts need to be folded

Adapter Brackets Wrapped in Paper and then put into Carton

Before Improvements:

Redesigned Packaging for Video Walls

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After Improvement:

New Inserts for Adapter Brackets

Replaced Inserts with

Corner Protectors

Projected Cost SavingsRedesigned Packaging for Video Walls

Per Unit Per Year

(EAU=24K)

Materials Savings = $1.55 $37,200

Labor Savings = $2.95 $70,800

Total Savings = $4.50 $108,000

Projected Annual Savings = $108,0007

Projected Cost Savings

Total Projected Labor Savings

Video Walls – New Packaging $108,000

Carts and Stands-New Layout $19,850

Extension Columns-New Methods $9,615

Total Projected Labor Savings $137,465

Total Projected Materials Savings $37,200

Projected Annual Savings $174,6658

Projects In ProcessDedicated Cells to Utilize Optimal Crew Sizes

Features:

Shop Orders routed to specific cells based on Crew Size

Cells are located across the aisle from staging areas

Next Shop Order is setup prior to completion of current order

Benefits

Increases productivity since work load is balanced

Scheduler schedules multiple orders

Cell leader knows in advance the next orders to run

Minimizes or eliminates downtime between orders

Cells with Dedicated Crew Sizes

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Cell C011 - Optimal Crew Size = 3

Projects In ProcessWork Cell Floor and Table Layout Template

Features:

Shows Material Handlers where to place containers of parts

Shows Cell Leaders and Workers:

what parts are required for each work station

where to place parts at the work stations

Benefits

Allows Material Handlers to perform part of the setup

Locates parts close to point-of-use

Minimizes travel distances between containers and stations

Minimizes or eliminates downtime between orders

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Developing

Cell Floor &

Table Layout

Templates