Smart Factory solution for Panel board furniture manufacturer
Case Study : Manufacturing
Overview
We were tasked to review & assess the business expectations such as tracking raw material consumption in operational steps involved from design to finished goods for India’s premier MDF panel board furniture manufacturer. We were provided access to review the entire process from design to Finished Goods at the factory shopfloor to identify solution to minimize scrap, damage & loss in raw material consumption.
Challenges (client shared & identified )
- Excessive dependence on the technical experience of engineers makes the company less process-driven & more individual-driven.
- Preparation of the Production part list takes a long time
- Manual intervention in the following processes leads to a loss in Material, Manpower & Machine time: Panel cutting, Panel Part routing
- Cut panel quantity and quantity that reaches the packaging stage do not match.
- WIP/Factory operated by temp/contract staff supported by experienced senior staff for
- tools handling experience
- quality expectations
- meet production schedule
Opportunity/Challenge
- Improve meeting production schedule
- Optimize delivery timeline with additional inventory
- Reduce wastage with raw material usage
- Improve the delivery lead time lost in manual work.
Solution
- Reduced time to market by 20 – 50%
- Reduced maintenance costs by 10 – 40%
- Increased productivity by 3 – 5%
- Reduced total machine downtime by 30 – 50%