Case Study 1-99683
IET worked with Mueller Industries to develop a new facility layout for physical distribution operations that consolidated multiple sites into one location.
A commercial and residential building products manufacturer
First, IET identified all active SKU’s and planned inventory levels. Storage assignment rules were developed based on SKU shipping activity and specific client requirements. Four design alternatives were evaluated for carton-packing operations using carton and pallet flow equipment to measure worker productivity. IET evaluated 3 design alternatives for surplus pallet storage utilizing high-density racking and NA/VNA lift truck technologies. Layouts were proposed to maximize utilization of the current facility with and without expansion. Staffing requirements were then estimated based on labor standards developed using pre-determined time study techniques. IET prepared budgetary cost estimates for material handling and storage equipment and facility modifications. IET worked closely with the client’s management team to obtain buy-in on all critical assumptions.
IET demonstrated that all outside facilities could be consolidated into one existing distribution center only by reducing overall planned inventory levels. IET assisted the client in developing rules for storing products in the proposed facility and provided the information needed to perform a detailed cost / benefit analysis on the recommended design. In addition, total pallet storage capability in the current facility was increased by 25%.