BIC Guides Edwards Lifesciences towards World Class Manufacturing!!!!
Edwards Lifesciences approached BIC in early 2008 to assist in the development of a World Class Manufacturing Center for their Transcatheter Delivery Systems in Irvine, CA.
Edwards Lifesciences’ Four Transcatheter production lines were designed under a pilot build scenario, where the design for manufacturability was not heavily considered. The lines performed a batch build manufacturing process, where production equipment is often shared and limited in daily output. Understanding this, Edwards set a course to update, automate and increase the output and reliability of the equipment in the manufacturing process. A goal was established to meet a very high rate of demand, with some lines increasing capacity 4-5 times their current production volume. A second important goal was to design ‘unique’ but flexible lines to produce products independently.
Within the first 3 months BIC identified and helped to implement the following improvements on one of the main production lines:
- Reduced Cycle time from 4 weeks to under 1 week
- Reduced monthly labor requirement for product lines from 450 hours to 150 hours
- Developed clear, concise and operator friendly Manufacturing SOPs
- Identified and reduced waste and travel time for Operators and Material
- Developed and implemented Visual Factory that is easy to supervise and is line-clearance friendly
Edwards Lifesciences has since extended BIC’s contract to create a World Class operation for the remaining product lines to include:
- Procurement / outsource of technologies to strategic partners with the intent to minimize manufacturing mistake exposure and to yield cost savings
- Coaching a team of engineers on ‘Best Manufacturing Practices’ and selection of capital equipment purchases
- Design and development of operator friendly catheter fixtures for drilling, cutting and skiving
- Identifying improvements that can be made through Lean Manufacturing – either in design for manufacturing or production based Lean methodology
Boston Industrial Consulting, Inc. continues to achieve success in assisting companies streamline their operation and increase their profit margin. Edwards Lifesciences joins an elite list of BIC Medial Device Manufacturers including Boston Scientific Corporation, Johnson & Johnson, Astra Tech, Inc. and CYTYC Corporation.
Tweeter Executes New Distribution Strategy!
The recent pressures on retail chains to drive down logistics costs, coupled with changes in store locations and physical sizes of electronics products, forced Tweeter to develop a new Supply Chain strategy. Tweeter commissioned a Supply Chain optimization study from Boston Industrial in late 2007 with hopes that a goal of 30% in cost reductions could be achieved.
Working closely with the Tweeter team, BIC developed a strategy for consolidation, along with a six-month implementation plan. This rapid deployment plan is underway, and has allowed Tweeter to obtain a high amount of savings in the early stages of implementation. The strategy will produce the following results:
- Consolidation of 4 Distribution Centers into 2 locations, significantly reducing operating costs
- Down-sizing of 3 other Distribution Centers to cut overhead charges
- Square Footage Savings of 300,000sf throughout the entire Supply Chain
- Projected Savings of over $5M in Supply Chain Costs
- Reduction of Tweeter’s Supply Burden by over 30% in a 6 month period
Tweeter and BIC worked collaboratively in the selection of new facilities, incorporating Tweeter’s operational needs and concurrently minimizing logistics costs. The Tweeter / BIC team completed the detailed design of new facilities, coordinated build-out with new landlords and created a smooth transition plan using internal and external resources. This role incorporated project execution to align MIS, HR and Operations departments to effectively transition to the new framework.
BIC has vast experience in helping companies design and implement Supply Chain cost reduction strategies in a seamless manner. Each client requires broad skill sets, attention to detail and day-to-day coordination activities; directed toward executing an overall project plan. Companies that have successfully utilized BIC services and reduced logistics costs include The Holmes Group, Party City and Vi-Jon, Inc.
BIC Provides Belimo Americas Relief for Growing Pains
Belimo Americas realized that they were outgrowing their current location in Danbury, Ct, but didn’t understand how to manage it without incurring the expense of relocation! Anticipating rapid Inventory and Sales growth, Belimo concluded they needed to seek help in finding alternative ways to be more efficient in their current building.
Belimo engaged BIC to identify specific current challenges and project future requirements over the next 3 to 5 years. BIC performed a detailed study of the current operations, quantifying average and peak congestion and cross-traffic between personnel and material movement. BIC also performed an extensive process review of Belimo’s Receiving, Storage, Replenishment, Production, Order Processing and Shipping operations.
While no single solution was discovered which would successfully meet all of the challenges, BIC identified a combination of improvements to maximize the efficiency and capacity of the facility. A transition strategy was developed for the next 5 years where daily production would not be significantly impacted, including:
1. Consolidation of Shipping and Packing functions to improve spatial utilization and improve material flow
2. Relocating production operations to improve facility layout, allowing for additional space for 26% more pallet storage
3. Implementing key components of a new WMS to improve workflow
4. Utilizing RF to direct product put-away and pick parts
By implementing the changes outlined, Belimo should be able to maximize their current footprint and operational efficiency while experiencing continued growth.
BIC’s many years of industry experience has allowed credibility in providing guidance to companies such as Belimo, Boston Scientific Corporation, Caterpillar and Massachusetts Medical Society over the past 11 years.
Boston Industrial Consulting, Inc. has recently completed the design of the largest customer parts branch for a large Caterpillar (CAT) Dealer Branch in Murrysville, PA utilizing a custom bin-sizing program specifically designed for Caterpillar. Utilizing BIC’s extensive exposure to industry best practices, along with years of experience with CAT Dealerships, the BIC slotting tool helps to maximize limited warehouse space and minimize new equipment expenditures.
Input for the tool has been designed to minimize effort using a standard information tool from Caterpillar's Mainframe unit. Standard output includes a detailed parts list for shelving, racking and other storage systems, along with a detailed list of locations for SKUs using proper cube and velocity.
The slotting output can provide a most efficient start or re-slotting for any branch parts depot operation.
BIC’s slotting program includes:
· Accurate slotting for the total number of storage units by type and part velocity
· Building sequence for storage systems based on the results of the slotting analysis, prioritizing faster moving parts in faster pick locations.
· Shelving schematics depicting number of levels, dividers, and spacing for each unit as well as weight and cubic capacities.
· Detailed pallet rack elevations.
· A detailed map for all locations open and occupied, formatted for import into a WMS or Host system.
· Segregation of parts as conveyable vs. non-conveyable based on part dimensions, shape and weight
Boston Industrial’s effort is greatly reliant on the CAT dealers’ internal capabilities and the selected vendors used for automation equipment and WMS implementation.
Project work for CAT dealerships has centered on designing effective and efficient Parts Depots and Stockrooms and increased shop efficiency programs. Boston Industrial continues to work with 6 Caterpillar Dealerships to help find ways to improve workflow and customer order turn time.
BIC Helps Vi-Jon Optimize its Supply Chain Strategy
Boston Industrial Consulting, Inc. was recently hired to perform a Supply Chain analysis to assist Vi-Jon, Inc. in the development of a Finished Goods Supply Chain Strategy.
Vi-Jon’s Manufacturing Plants and Distribution Centers, located in Missouri and Tennessee, produce Private Label Health and Beauty products. Goods are manufactured, palletized and transported to Distribution Centers in close proximity to plants.
BIC evaluated existing baseline operational needs against several logistics options to determine the most efficient strategic plan for Vi-Jon’s Supply Chain. This process included:
- Developed data requirements for analyzing the Finished Goods Supply Chain Strategy
- Reviewed the cost structures for baseline options for transportation, along with proposed consolidation options with the goal of improving customer services overall
- Evaluated benefits of consolidation and performed analysis to quantify efficiency opportunities
- Quantified supply chain options in greater detail, providing a more accurate understanding of Logistics and Finished Goods Warehouses
BIC continues to work with Vi-Jon, Inc. to perform an overall needs assessment of Distribution space over the next 1-5 years. Once fully understood, a detailed Supply Chain strategy will be developed for distribution facilities to closely match needs versus available space.
BIC continues to help companies such as Vi-Jon, Inc., Amscan / Party City and Caterpillar dealerships realize their maximum potential in customer service relations.
GSI hires Boston Industrial for Multi-Phase Operational Improvement Program
GSI Group, a leading manufacturer of equipment to the Semi-conductor business, has hired Boston Industrial Consulting to evaluate the current production and supporting operations for its Wilmington, Billerica and Natick, MA operations. The initial Phase included identification of operational improvements and development of area requirements for a consolidated operation. Secondary phases included detailed layout planning, process documentation and implementation coordination.
A significant square footage reduction was accommodated through the consolidation of multiple operations into a central location. Consolidation of locations will provide signifigant operational and cost benefits, including:
- Efficient area for common departments through co-location and consolidation (eg. Shipping, Receiving, Incoming Inspection and Warehousing operations).
- The implementation of denser storage systems through the use of improved fork trucks and carousel systems.
- The right-sizing of departments, incorporating benefits of Lean Manufacturing and elimination of unused space provided significant reductions in the manufacturing operation.
- The promotion of more open work centers to accommodate multiple machine types allowed for improved use of space and a more adaptable manufacturing environment.
- Reduced aisles maximized flexibility.
During the process, BIC developed multiple test fits and block concepts for the consolidated facility, each meeting the requirements of improved manufacturing processes and layout. The approved plan has allowed detailed design to commence. Layouts for all individual pieces of equipment will be developed, identifying Mechanical, Electrical and Plumbing tool hook-up services.
This is the first of several project phases to be performed by Boston Industrial for GSI Group, who joins the list of prominent companies to solicit BIC’s assistance for company-wide improvements, including Boston Scientific Corp., Magellan Aerospace and Caterpillar.
Subaru New England Hires BIC to Improve its Parts Depot
Boston Industrial Consulting has been hired to assist Subaru New England to design and improve its Parts Distribution operation in Norwood, MA.
Subaru of New England is an independent distributor of Subaru parts operating in over 52,000sf in its Norwood warehouse. The operation distributes Subaru automotive parts to over 70 dealers in New England, with a turn time of 3 to 4 hours from order entry to shipping. The operation is able to support their customers with a fill rate near 100% by housing an SKU base well above 11,000 items. The operation receives, picks, packs and ships orders over a 2-shift process, often delivering to all of its customers on a daily basis in a quick and high quality manner.
Over the past several years, growth has been significant, and has created pressure on warehouse areas. High growth of orders and SKUs has also limited the ability to distribute parts in a cost effective manner. With growth projected to continue, Subaru has elected to secure an adjacent building to house its office personnel, freeing up space for a necessary expansion of storage and parts processing space.
A study of the operations will be performed to identify improvements to the systems, processes and equipment to meet the growing demands of the business. A physical expansion and schematic plan will be developed to effectively accommodate an increase in storage and dock areas. Improved process and systems will be evaluated such as zone picking, faster picking equipment and an improved WMS. Solutions will help Subaru continue to provide exceptional service to its customers, while reducing costs for internal operations below present levels.
BIC will be working with Subaru through multiple phases of this project until an efficient solution is fully operational. Boston Industrial continues to build its resume of parts depot centers, including 7 Caterpillar dealerships and other automotive parts operations.
Boston Industrial Consulting Completes Phase 1 Implementation for Ellanef Manufacturing!
Ellanef Manufacturing, a division of Magellan Aerospace located in Corona, NY, recently teamed with Boston Industrial to successfully complete Phase 1 of their Operations Consolidation. Ellanef, a manufacturer of structural components and sub-assemblies for the Military and Commercial Aerospace industries, consolidated 7 manufacturing facilities into 4 without any delays to customer shipments.
Ellanef previously operated from 7 independent buildings totaling over 120,000sf within a heavily populated section of Metropolitan New York. Faced with a need to increase productivity and reduce material handling costs, as well as the overall burden of square footage to the business, Ellanef set out to create a long-term plan to consolidate its operations. A long-term multi-phase plan was assembled. Phase 1 involved the goal of consolidating to 35,000sf less space, which then resulted in reduced operational burdens. The need to rationalize and eliminate unused equipment, improve material handling and implement lean techniques to the design was critical to meet the desired spatial and cost reduction goals.
The project commenced in early April, and within one month improved manufacturing layouts and material handling systems were approved. A detailed master phasing strategy and tactical transition plan for each equipment move was developed with the Ellanef team. In order to meet the aggressive schedule for a December 2006 completion, multiple internal teams were formed, with BIC worked ‘arm-in-arm’ to lead and help execute the plan. Project highlights and accomplishments include:
· » Reduced square footage burden from 120,000sf to 85,000sf
· » Elimination of over 100 pieces of underutilized equipment
· » Reduced total travel distances by over 20%
· » Experienced no business interruptions or delay of customer shipments
Boston Industrial continues its partnership with Magellan Aerospace, helping find ways together to improve efficiency, workflow and employ lean concepts throughout their operations.
This is Boston Industrial’s second project with Magellan Aerospace; the initial project involved the development of lean layouts and processes for the relocation of the Middleton Aerospace division in Haverhill, MA. Boston Industrial’s success has been greatly reliant upon Magellan’s strong internal leadership and a total commitment by all team members to the project.
About BIC...
Founded in 1996, Boston Industrial Consulting, Inc. is celebrating its 10th Anniversary as a leader in Industrial Engineering and Operational Efficiency. Our clients include Caterpillar, Boston Scientific Corp., Tiffany & Company, Hallmark Cards, GE, and ThermoFisher.
For more information or to contact us:
Send an e-mail to: Bob Liptrot, President
Or, visit our website for more information.
Specialty Catalog Hires Boston Industrial to Design its New DC!
Specialty Catalog Corporation, the nation’s largest direct marketer of Wigs and Hairpieces, has recently commissioned Boston Industrial Consulting, Inc. to design its new Distribution Center in West Bridgewater, MA.
Specialty Catalog Corp. (also known as SC Direct) serves the fashion and medical hair-loss industry through catalogs, websites and direct marketing in the United States and abroad. The operation, which currently distributes over 20 million catalogs to over 2 million households annually, is limited in its current location capacity and output. Specialty Catalog, previously hired BIC to evaluate its current operation and develop a distribution strategy, recognized the need for improved distribution capabilities, to meet new ownership objectives of improved quality and reduced costs.
Initial studies indicated that significant improvement would be gained if the operation relocated to a new, more modern facility. Working with Boston Industrial, Specialty Catalog selected a new 130,000sf facility in West Bridgewater, MA. Boston Industrial Consulting was commissioned to lead the design, specification and implementation of its new distribution center.
The proposed operation will employ more automated picking and packing systems to reduce the amount of material handling costs. Current operation systems will be enhanced with more use of bar-coding and system directed activities to expand efficiency and improve picking accuracy. The new operation will allow increased capacity, improved customer turnover time and lower unit costs for distribution.
This marks Boston Industrial’s third project over the past two years with Specialty Catalog Corp. The completion of this phase and the relocation to the new DC will occur in late summer of 2007.
About BIC...
Founded in 1996, Boston Industrial Consulting, Inc. is celebrating its 10th Anniversary as a leader in Industrial Engineering and Operational Efficiency. Our clients include Caterpillar, Boston Scientific Corp., Tiffany & Company, Hallmark Cards, GE, and ThermoFisher.
For more information or to contact us:
Send an e-mail to: Bob Liptrot, President
Or, visit our website for more information.
Century 21 Department Stores Hires Boston Industrial for its NEW DC!
Century 21 Department Stores, New York's leading discount retailer has recently hired Boston Industrial Consulting, Inc. to assist in the design and simulation of its new Distribution Center in New Jersey.
Century 21 Department Stores was established over 40 years ago, and has a reputation for offering high quality merchandise at discount prices. The retail operation consists of 5 high-volume locations, with expansion plans to make a greater presence in the New York / New Jersey area over the next 5 to 10 years. The need to accommodate high growth, as well as reduce its total distribution costs, drove Century 21 to a decision to consolidate its operations into a new Distribution facility.
Century 21's new DC will employ the efficient use of automated material handling systems, and improved process methods for processing, picking and packing. The operation's dynamic nature, involving hanging, flat, and carton product for its nine key business units, will incorporate a new Warehouse Management System as well. New processes will employ state of the art control systems to effectively cross-dock, transport, store and ship product efficiently to their stores. Occupancy is planned for 2008.
Boston Industrial Consulting will assist Century 21 Department Stores and Material Handling Suppliers in the design, project management and simulation of the new distribution operation. Boston Industrial Consulting will work closely with Century 21 Distribution Leaders to establish an efficient and effective operation, as well as balancing storage and material handling efficiencies to meet the growing demands of the retail business.
Boston Industrial Consulting continues to grow its retail capabilities by adding Century 21 Department Stores to its retail client list, which already includes Party City, Tiffany & Co. and Zappos.com.
About BIC...
Founded in 1996, Boston Industrial Consulting, Inc. is celebrating its 10th Anniversary as a leader in Industrial Engineering and Operational Efficiency. Our clients include Caterpillar, Boston Scientific Corp., Tiffany & Company, Hallmark Cards, GE, and ThermoFisher.
For more information or to contact us:
Send an e-mail to: Bob Liptrot, President
Or, visit our website for more information.
Boston Industrial to Design 3 Western CAT Parts Depots!
During the first quarter of 2007, 3 of Caterpillar's Western Dealers commissioned Boston Industrial Consulting (BIC) to redesign, improve or expand their Parts Depots. This currently increases BIC's total CAT dealership involvement to 6 dealers.
In January 2007, Empire CAT, one of the country's largest volume dealerships based in Mesa, AZ, hired BIC to make operational improvements to its current parts stockroom. Improvements were aimed at increasing capacity and throughput, as well as truck loading efficiencies ina limited footprint. A second project with Empire is also in progress, involving the Master Planning for a new site to include a larger Parts Depot and Equipment Shops. This operation will employ more automated and space efficient equipment than the conventional systems currently employed in many CAT dealerships.
Cashman CAT, which serves the majority of the Nevada territory, hired BIC in February 2007 to plan, justify and make recommendations for automation and system enhancements in two of its larger parts operations. These two Parts Depots are currently under study, and the solutions presented will have an unbiased Return-on-Investment analysis for improved systems developed prior to management approval.
Wheeler CAT, located in Salt Lake City, is another large western dealer undergoing heavy growth in line volume and total activity. The parts operation is based with the need to accommodate several more years of growth in an already limited footprint. BIC will work with Wheeler's internal group to evaluate, analyze solutions that will improve efficiency and customer turn time, while meeting the ROI justification threshold.
Boston Industrial continues its partnership with Caterpillar Dealerships, helping find equipment and systems to improve efficiency, workflow and customer order turn time. These additions increase Boston Industrial's client base to six CAT dealerships. Project work for CAT dealerships has centered on designing effective and efficient Parts Depots and Stockrooms for CAT, and has increased in scope to shop efficiency programs. Boston Industrial's success on these projects has been greatly reliant on the CAT dealers' internal capabilities and the selected vendors used for automation equipment and WMS systems implementation.
About BIC...
Founded in 1996, Boston Industrial Consulting, Inc. is celebrating its 10th Anniversary as a leader in Industrial Engineering and Operational Efficiency. Our clients include Caterpillar, Boston Scientific Corp., Tiffany & Company, Hallmark Cards, GE, and ThermoFisher.
For more information or to contact us:
Send an e-mail to: Bob Liptrot, President
Or, visit our website for more information.
BIC Design Maximizes Cleveland Brothers CAT Warehouse Efficiency!
Cleveland Brothers Caterpillar, one of the country’s largest dealerships, worked with BIC over the past 2 years to create an efficient parts depot encompassing facility design and development of storage requirements for their new 85,000sf Parts Distribution Center in State College, PA. The DC, while supporting a large cross-dock and retail store, mainly services 30 branches throughout 78 Mid-Atlantic counties, as well as their own repair operations.
This state-of-the-art facility incorporates proven technologies, including Put-to-Light Order Picking, Pick-n-Pass Conveyance, and Warehouse Management / Control Systems.
BIC’s involvement incorporated a multi-phased approach:
- Master Planning, which focused on right-sizing the facility, developing efficient and automated operational processes, pick technology and storage / handling equipment to work in accord with the new WMS.
- Detailed Design, which included the development of detailed layouts, specifications, warehouse storage and delivery processes to meet the physical demands of the Parts Depot. Vendor bidding and selection of equipment suppliers was also included in this phase. In addition, BIC assisted with the development of detailed processes and specifications for the WMS to meet the expected operational efficiencies as defined in the Master Plan.
- Implementation, included the coordination of equipment installation, building systems, software, slotting and relocation of physical operations to the new facility. Software coordination, process refinement, testing assistance, training, and total project coordination of all parties was a main concentration to assure timeline, budget and performance expectations were met.
This success story illustrates how Boston Industrial Consulting continues to build and strengthen its relationship with Caterpillar Dealerships throughout the United States to enhance their Parts Depot business. Cleveland Brothers CAT joins a growing list of CAT Dealerships, including Cashman CAT, Empire CAT, J. A. Riggs CAT, Milton CAT, Wagner CAT and Wheeler CAT; all who recognize the capabilities that BIC can offer to guide them through proper changes to keep their business growing and clients well-served.
About BIC...
Founded in 1996, Boston Industrial Consulting, Inc. is celebrating its 11th Anniversary as a leader in Industrial Engineering and Operational Efficiency. Our clients include Caterpillar, Boston Scientific Corp., Tiffany & Company, Hallmark Cards, GE, and ThermoFisher.
For more information or to contact us:
Send an e-mail to: Bob Liptrot, President
Or, visit our website for more information.
