2. Identified Opportunities to
Increase Productivity
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• Updated designs for packaging and cell
layouts for high labor content products
• SR560M and other carts and Stands
• DS-VW765-LAND – Video Wall
• Dedicated cells to run shop orders with
optimal crew sizes
3. Redesigned Layout for Carts & Stands
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Start of the Line: 1 Piece Carton
Placed on Conveyor
Components packed at tables
Staples replace tape
End of the Line: 1 Piece Carton End of the Line: Pallet located next to
aisle for easy access by forklift
4. Projected Cost Savings
Redesigned Packaging and Layout for Carts
Before Improvements:
25 units/hour with a crew size of 7 people
EAU = 7,136 units/year – 2,000 labor hours
After Improvements:
28 units/hour with a crew size of 6 people
EAU = 7,136 units/year – 1,529 labor hours
Total Labor Hours Saved = 471 hours
Labor Rate = $42.14/hour
Estimated Total Annual Savings = $ 19,850 4
5. Redesigned Packaging for Video Walls
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Carton is too deep –
requires extra filler paper
Inserts need to be folded
Adapter Brackets Wrapped in
Paper and then put into Carton
Before Improvements:
6. Redesigned Packaging for Video Walls
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After Improvement:
New Inserts for Adapter Brackets
Replaced Inserts with
Corner Protectors
7. Projected Cost Savings
Redesigned Packaging for Video Walls
Per Unit Per Year
(EAU=24K)
Materials Savings = $1.55 $37,200
Labor Savings = $2.95 $70,800
Total Savings = $4.50 $108,000
Projected Annual Savings = $108,000
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8. Projected Cost Savings
Total Projected Labor Savings
Video Walls – New Packaging $108,000
Carts and Stands-New Layout $19,850
Extension Columns-New Methods $9,615
Total Projected Labor Savings $137,465
Total Projected Materials Savings $37,200
Projected Annual Savings $174,665
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9. Projects In Process
Dedicated Cells to Utilize Optimal Crew Sizes
Features:
Shop Orders routed to specific cells based on Crew Size
Cells are located across the aisle from staging areas
Next Shop Order is setup prior to completion of current order
Benefits
Increases productivity since work load is balanced
Scheduler schedules multiple orders
Cell leader knows in advance the next orders to run
Minimizes or eliminates downtime between orders
11. Projects In Process
Work Cell Floor and Table Layout Template
Features:
Shows Material Handlers where to place containers of parts
Shows Cell Leaders and Workers:
what parts are required for each work station
where to place parts at the work stations
Benefits
Allows Material Handlers to perform part of the setup
Locates parts close to point-of-use
Minimizes travel distances between containers and stations
Minimizes or eliminates downtime between orders