Flow Planner Presentation Selected Case Studies

Internet / Intranet based Process Engineering Flow Planner Features Analyze an unlimited number of flow paths and material handling methods Include user-defined pick-up and set- down times linked to material handling methods, container types or locations Set path segment thickness according to flow intensity Import and export using simple text files

Internet / Intranet based Process Engineering Flow Planner Features Filter flow paths by product, part, material handling device or combination of two. Automatically create straight-line flow paths, aisle-based flow paths and manually create user-defined paths Aggregate flows from different primary and secondary sort fields to evaluate “total flow” and congestion along routes and aisles Automatically label flow paths with segment and total distances

Internet / Intranet based Process Engineering Flow Planner Case Study Initial Flow at Electronics Assembly and Test Area Flow is lengthy and unorganized with frequent backtracking. Not dedicating equipment by product resulted in many lengthy set up times and lower asset utilization. First step of Flow Diagramming is to move areas that are linked by the same color closer together.

Internet / Intranet based Process Engineering Flow Planner Case Study Revised Flow at Electronics Assembly and Test Area Products grouped into three modules created more streamlined flow and decreased throughput time. The company had spent 4 million dollars on layout changes in 5 years without using layout tools. In one layout project they reduced material handling travel distance by 35% which was a savings of over $300,000 with an increase in throughput by 22% and reduction of material handling defects by 15%.

Internet / Intranet based Process Engineering Flow Planner Case Study New Shifter Line at Automotive Supplier Proposed location for the new generation automotive shifter assembly line. Actual path part flow within facility.

Internet / Intranet based Process Engineering Flow Planner Case Study Actual Flow of Materials to the Shifter Area Actual path of part flow within facility and to shipping area. Optimized storage locations reduced flow by over 40 percent. $94,000 per month saved by moving high volume area near shipping

Internet / Intranet based Process Engineering Benefits of using Flow Planner Quantified factory layout metrics ensure that changes are actually improvements Better quality layout designs produced in less time Flow diagrams help layout teams visualize, understand, communicate and improve flow Smoother, more organized flow can positively affect critical manufacturing metrics like asset utilization, throughput time, operating expenses, and inventory levels Estimate material handling resource requirements Evaluate layout driven changes –Equipment placement –Storage placement –Dock placement –Department and cell placement –Aisle sizing and orientation

Internet / Intranet based Process Engineering Flow Planner Helps Reach Goals Current Situation –Need for process improvement –More products being produced Flow Planner Benefits –Verify factory designs before implementation –Reduces facility planning time –Compress time to launch new products –Bring mfg facilities on line faster –Improves production efficiency –Improves industrial engineering efficiency