Deli Slicing Case Study
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.
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