After performing analysis on sales data and marketing projections, EFI Group coupled tube-making and printing equipment to simplify the overall manufacturing process. Additionally, EFI Group redesigned the layout, connecting the tube-making and printing operations.
The solution reduced space requirements for WIP and finished goods inventory, freeing space for additional screen-printing equipment to support the plant’s fastest growing and most profitable products.
EFI Group also analyzed production processes and sales and marketing data and recommended work process changes that would increase efficiency.
The client manufactures plastic tubes for food products, toiletries and cosmetics. Tubes are produced in over 100 different size and shape configurations.
The process involves an injection molding step and a printing step. Prior to EFI Group’s involvement, blank tubes were first made and stored in inventory. Then, when printing plates and inks were available, tubes were taken from inventory, printed and re-inventoried. These separate manufacturing activities wasted production and warehouse space and complicated the manufacturing planning processes.
The goal was to design a strategy that would combine the tube-making and printing operations in order to minimize inventory space and improve lead time. By reducing inventory space, the client would be able to expand their production operation.
After analyzing production requirements using production and sales data from the preceding two years, EFI Group developed a plant layout that combined the tube-making and printing steps.
Additionally, EFI Group interviewed marketing personnel to gather data for future product trends. This data was summarized to determine “product families” for all product types and then used to develop specific equipment arrangements that would match tube-making and printing operations in support of each product family.
- Market analysis of production requirements broken down into five “product families,” including a breakdown of both “standard” and “custom” products.
- General arrangement of a proposed new plant layout.
- Detailed drawings of molding-to-printer equipment connections.
- Implementation plan for moving equipment while maintaining full production.
- Cost estimate for the project.