When manufacturing operations look to optimize their workforce, improve productivity, reduce time to market, increase efficiency or maximize inventory, turning strategy into action can be overwhelming. Success depends on translating big-picture objectives into practical, measurable improvements on the shop floor.
“Manufacturing consultants are brought in to identify the root cause of any production challenges and determine the best path forward for the client,” Haskell Vice President Keith Perkey said. “We do this on active projects or existing facilities and operations.”
Haskell’s manufacturing experts have over 200 years of combined experience optimizing capital deployment, maximizing labor productivity, enhancing overall system efficiency and performance, improving reliability and minimizing waste.
Assess, Identify, Optimize
When an international contact lens company needed help preparing its existing operation for a projected 75% increase in production, Haskell engineers developed a simulation model of the company’s manufacturing process, comprising automated and manual processes, and analyzed the output.
The team identified bottlenecks and capacity constraints, including a poorly running line with excessive machine stops and more than 30 different stock-keeping units (SKUs) that were causing reduced throughput, increased scrap and lost time.
An assessment of the existing system identified the most financially justified equipment for optimizing capacity and included a material-flow analysis. The final step involved simulating and fine-tuning a detailed virtual layout and debugging controls virtually to prepare for startup.
The result was an optimized, executable plan that created value, reduced wasted time and cost, and aligned with the client’s business strategy.
“Capacity optimization models help manufacturers consider how decisions about production equipment impact their ability to fulfill orders,” Perkey said. “Our Manufacturing Consulting team also developed a master plan that helped our client decide the most productive way to invest capital over a planning horizon to meet manufacturing goals.”
Cutting Waste, Time and Cost
When a milk manufacturer wanted to consolidate 29 dairy facilities – which collectively produced 110 million gallons of milk annually – into one, Haskell’s Manufacturing Consulting team worked to reduce the number of production lines from four to three, thereby reducing the manufacturing footprint. By minimizing utilities, maintenance and operations, the owner realized $3.7 million in savings.
Another consumer-packaged goods manufacturer needed additional time on its current manufacturing lines to accommodate new products. Haskell’s team was asked to analyze customer demand profiles and, using the manufacturer's existing asset base, created an optimized scenario that allowed four hours of additional production time.
“We are frequently asked to help clients with their existing production processes,” Perkey said.
In another case, a paper products manufacturer had complex SKU profiles that were further complicated by the plant's capital upgrades to add production lines. Each line had unique reliability, SKU capabilities, changeover times and run speeds. Standard enterprise resource planning (ERP) tools couldn’t handle the task of scheduling a single process system across many production lines.
“We delivered a custom production planning tool that included a mixed-integer programming model and a custom software interface that the plant team would run daily,” Perkey said. “The scheduling tool was validated with discrete-event simulation and extensively tested before being integrated with daily operations. Additionally, the team provided full life-cycle support, including validation of results and end-user training.”
When extra capacity is needed, manufacturing consultants deliver a route to the most cost-effective solution, including system refurbishment and upgrades, a faster and more automated footprint and facility expansion and/or consolidation. Their plans help manufacturers avoid unnecessary spending and determine when to trigger capital improvements.
Simply, when change is needed, manufacturing consultants can provide a roadmap to keep businesses running smoothly.
