Manufacturing Process Improvement
![Chemical processing [© iStockPhoto.com/Dainis Derics]](/images/practice-areas/000001160649.jpg)
Applying EFI Group’s experience and technical expertise to your manufacturing processes results in reduced operating costs, increased productivity and improved quality. EFI Group uses techniques based on Lean Manufacturing principles to identify opportunities and implement solutions.
Production Rate Improvement for a
Major Sugar Refiner
After EFI Group involvement, a major sugar refinery achieved a 10% productivity improvement through their consumer packaging process. EFI Group performed a constraint analysis on the vast network of feeders, screw conveyors, bucket elevators, and other conveying equipment to identify problem areas. The team designed and implemented several conveying system changes within a short time frame that did not require capital investment. Equipment reliability has remained high, and the client continues to implement items from EFI’s recommendation list.
Reduced Energy Cost for an HVAC
Equipment OEM
EFI Group enabled an OEM client to establish a basis for immediate and future energy cost reduction at a large facility. EFI was tasked with analyzing and quantifying the impact of utility cost on operational cost. The EFI team quantified the facility’s various utilities based on their relationship to production output, and presented findings in a graphical format with specific reduction opportunities. By linking individual processes to their respective utility costs, the client was able to treat utility costs as a controllable operational budget item rather than a relatively uncontrollable fixed cost.
Increased Production at Plastic Tube Manufacturer
After performing analysis on sales data and marketing projections EFI coupled tube-making and printing equipment to simplify the overall manufacturing process. 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 redesigned the layout connecting tube-making and printing operations, and recommended work process changes after analyzing production processes and sales and marketing data.
$700,000 Water Usage Refund Achieved
EFI identified opportunities to reduce municipal water usage and reconcile costs shown on city water bills. The EFI team completed a water balance for the entire 200-acre site using plant metering corrected with EFI’s portable meters. Cost information was calculated from the survey and from water bills going back several years. EFI was able to prove that city meters were reading high. The client recovered over $700,000 in back payments from the city.
Increased Packaging Line Capacity for a
Major Sugar Refiner
EFI’s work enabled the client to implement several new packaging lines for sugar products ranging from 2-pound bags to 2200-pound super sacks. EFI performed site visits and developed a sugar feed system approach and design. The team then completed the packaging machine layout, and designed all structures and access platforms. Five packaging lines were successfully installed and continue to operate.