Case Study

Background

A health and beauty company wanted to increase their production capacity from 5,000 to 10,000 units per week. Historically, they operated with separated batch processes for mixing, filling, boxing and labeling. The client needed a clear understanding of their existing capacity and to have a roadmap created for doubling their capacity.

Solution

After establishing takt time based on future demand, an exploration of efficiency, staffing and capital options to grow was conducted. Firefly worked with the client to document the current baseline and bottleneck steps. Value stream mapping and process loading charts were developed based on observation and analysis of the current process. In order to meet the higher capacity, the team balanced the process and created two Lean production cell options along with recommended equipment and staffing requirements.

Results

Recommendations were provided on how to further improve efficiency an additional 20-40% with a capacity roadmap. The client is purchasing components and changing production layout to test the new production cell design in their current locations. They plan to reengage our team to help them with their production relocation.

Want to see results like this at your company? Contact our team to learn more.