OPTIMIZE & OVERCOME
SITUATION
Freshdirect was in the design phase for their new flagship facility and was looking for efficiencies in their MTO (Make-to-Order) Production Stations.
THEIR NEED
Develop a "Single Cell Manufacturing" slicing & confirmation station with at least
10% productivity gains for
the Deli operation.
PRIMARY SERVICES PROVIDED
- Analyze production waving set up (MRP logic) and consolidate to lower product handling for each production wave.
- Design ergonomic production station that allows for 1-& 2-person staffing.
- Align room design with station layout for efficient flow.
- Create Raw Material flow from warehouse to production rooms including food Safety Prevention Step, WIP storage and ERP system driven replenishment flow to each station.
- Smart automation for Finished Product flow out of the department.
- Develop High Speed Solution for select high volume products with automatic weight and label application flow in a "batched" production environment.
RESULTS
Enhancements yielded 1.5h product handling time reduction per FTE (Full Time Employee) shift and a overall efficiency gain of 18-25% depending on station type. Overall department labor efficiency gains where in the low 30% mark from old to new facility.
TELL US ABOUT YOUR PROJECT
We’d love to hear from you. Choose the most convenient method and we’ll get back to you as soon as we can.