Projects

Reducing Operational Costs by 1M EGP/month by utilized machines

About the Factory

One of the top manufactures in Egypt established in 1975, specialized in Hardwood and engineered wood kitchens and showrooms that produced in top quality.

Problem Statement:

7 factories sharing a building, each of them has the same workstations, after defining their process and measuring their capacity and production volume, a total of (111) unit from workstation 1 were produced in 3 months; and (5.5 M) unit from workstation 2 in the same period; workstation 1 and 2 for the 7 factories occupies area of 242 m2. With the available resources of manpower and number of machines, the 7 factories were capable to produce (170) unit from workstation 1 and (7 M) of workstation 2. As a result, manpower utilization for workstation 1 was (56%), and manpower utilization at workstation 2 was (64%)

Objective:

·        Increase manpower utilization at these areas by 20%.

·        Reduce number of machines from 19 to 11 .

·        Reduce spaces dedicated to these workstations by 92 m2.

·        Set production planning protocol.

·        Decrease operational Expenses by 1 M EGP annually.

·        Increase planned work / total work.

Methodology:

·        Setting number of facilities that needed for proposed project.

·        Setting process flow.

·        Creating job description for each position.

·        Creating new hierarchy (org structure).

·        Setting production planning protocol.

·        Setting work instructions for centralized area.

·        Design Layout.

·        Design Needed Templates to track the whole process.

·        Layout preparation, and machine setup.

·        Calculate space savings by this project.

·        Select workers of central wax area.