Removal to new plant and processes optimisation

Need

The current distribution in the plant is the result of the factory evolution in the last years:

• Discontinuity of the productive flow: locations far away from the supplier – client process
• “Crossed” material flows by the mentioned layout and by the necessity to realise more than one process phase in the same equipment
• Unsuitable handlings: need to use wheelbarrows  to supply coils to presses out of the monorail alignment
• Machines orientation not suitable to the need of equipment supervision (1op / 2 equipments)

The removal to a new building is an opportunity to optimise the process in terms of equipment, material flow, warehouses and storage systems, work shifts, and available handling means.

Solution brought

Definition and monitoring in the new lay-out implementation following the next steps:

• Design hypothesis definition with future prevision
• In plant distribution definition:
  • Warehouse sizing
  • Bloks alternative analysis
  • Detailed lay-out selection and development
• Functional specifications of civil work and installation definition
• Budget definition and removal plan
• Implementation monitoring

Main achievements

• Implantation of islands of stamping (head of the process) for the materials handling optimisation and the supervision of the equipment (collision’s reduction in the equipment’s attention)
• Equipment removal to the new locations in 3 weeks