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800-319-0259
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For a major manufacturer of food products, designed a new material handling system to transport raw material, work-in-process and finished goods between eight manufacturing floors and two warehouses. Developed functional bid specifications for a new material tracking system to provide system control real-time. The new system provides for 50% more throughput while reducing material handling labor by 25%.
For a large produce wholesaler and distributor, developed a new distribution center design. The new plan utilized pallet flow rack, push-back rack, drive-in rack, double deep rack and selective pallet rack configured in seven separate climate zones. Better space utilization allowed the client to remain in their existing facility while growing 15% per year over the planning horizon. Converting to a zone-batch order selection methodology resulted in over $1 million in annual labor savings.
For a large producer of boxed beef and pork, designed and implemented four new “green field” cross-dock warehouses to support a re-engineered supply chain. Responsible for all aspects of the facility roll out including site selection, facility design, material handling system design, equipment procurement and installation, information system functional specifications, staffing plans and start up.
For a growing sausage producer, documented current material handling procedures as training materials for interface with proposed warehouse management system. Performed inventory analysis for in-house capacity planning and created decision model for 3PL storage alternatives during peak production periods. Identified material handling improvements to complement proposed capacity increase in meat processing.
For a leading snack food producer, performed analysis of shipping capacity for direct-to-store retail deliveries as a network consolidation initiative. Current network consisted of three hundred distribution “sales centers” nationwide. Facility classifications were developed to easily identify existing and unutilized shipping capacity. Recommended improvements included receipt scheduling, automated material handling of completed orders, truck loading and delivery route optimization.
For a leading producer of prepared meat products, documented material handling process for a multi-level manufacturing facility. Performed analysis to streamline vertical movement of bulk product and packaging materials. Product materials included raw meat, additives and spices, in-process inventory and finished product. Considerations included available inventory, lot size, product contamination, product-curing times, equipment capacity and facility expansion.
For a recognized wine & spirits wholesaler, performed analysis of current bottle handling methods to recommend improved order fulfillment operation. New batch-picking solution consisted for four horizontal carousels, carton-flow zoning strategy, reassigned product locations and increased order accumulation for proper routing. Productivity improvements resulted in labor reductions, balanced workflow and sustained case loading rates.
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