Case Study 1-09778
Streamlining multi-facility flow.
IET evaluated the current production system and worked with the new facility
design team to streamline a new single floor facility design.
A leading manufacturer of smokeless tobacco products, who produces hundreds of variations of chew tobacco products for the world market.
This process has evolved over the past fifty years and now encompasses three different
buildings on multiple levels. Material flow to and from the line is a critical component of
effective utilization and the disrupted layout and limited work areas have created varied
constraints in the production system. A new facility plan is being considered and improved
material flow will be a critical component of this new capital investment justification.
IET evaluated current constraints, inventory and line stocking strategies, indirect labor
requirements and overall material flow and worked with the new facility design team to
streamline a new single floor facility design. Utilizing at-point-of-use storage, kanban line
restocking, visual control systems, and lean inventory strategies, IET supported the new
designs to actually reduce planned space requirements by nearly 40%. In addition, IET
engineers assessed the specific labor requirements and improved line performance factors to
establish confident improvements to assess cost-benefits of the new facility investment.
Specific layouts and staffing models were developed to support and minimize the total space
requirements. The client is moving forward with the single facility design implementation.
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