Capacity Optimization

$2B Polymer Processing Systems Manufacturer

Background

  • A $2B global manufacturer specializing in polymer processing and dispensing systems
  • Products include systems and original equipment manufacturer (OEM) replacement parts such as screws, barrels, and filtration systems

Contributions

  • Created value stream and spaghetti maps for all domestic plants and product groups for barrel and screw manufacturing
  • Created dynamic capacity modeling tool
  • Performed bottleneck analysis at to validate new equipment affects on available machine hours

Results

  • Capacity modeling tool allowed plants to load forecasts in units and see net effect on machine utilization, staffing requirements, and current OEE losses which improved capacity and line leveling across the organization
  • Created current and future state value stream maps which resulted in an in-depth continuous improvement (CI) program