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Boston Industrial Profiled in Material Handling Management

2010-02-03T11:08:00.000-05:00

Doing More With Less

Boston Industrial's project with one of Caterpillar's largest dealers was recently profiled in the November 2009 edition of Material Handling Management. Instrumental to the success of the Cleveland Brothers Equipment parts depot was the design and integration of efficient processes, equipment and WMS using TECSYS as the software backbone. The article, entitled "Doing More With Less", highlights the efforts of BIC and the project team in developing and implementing practical solutions in a dynamic environment. The title of the article echoes a common theme for successful Supply Chain organizations operating in the 2010's - 'How do we do more with less?'

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Boston Scientific Operates World Class Manufacturing Center in Costa Rica

Boston Industrial Expands Its Simulation Capabilities

Bluefin Hires BIC to Create its Expanded Manufacturing Center

Boston Scientific Operates World Class Manufacturing Center in Costa Rica

2010-01-20T15:33:00.002-05:00

Boston Scientific recently opened its World Class Manufacturing Center of Excellence in San Jose, Costa Rica. President Oscar ARIAS Sanchez assisted in the ribbon-cutting ceremony, and commented that the Manufacturing operation will be one of the most efficient in Costa Rica history, and the Country's first LEED certified building.

Boston Scientifics' goal at the project onset was to create an Operations Center of Excellence for Medical Device Manufacturing, while operating under the regulations of FDA and GMP guidelines. The result is a 270,000sf World Class Manufacturing facility that will be at the center of Boston Scientifics' manufacturing future.

Boston Industrial was instrumental in assisting Boston Scientific reach their goal through:

Detailed Programming of Manufacturing spaces and adjacencies
Involvement in BOD for Manufacturing and Warehouse spaces
Detailed Manufacturing and support area equipment layout
Efficient material handling and management flow throughout the operation
Improved personnel workflow into and out of Clean Room spaces
Design of Lean and Kanban systems for efficient parts deliveries
Vendor selection and implementation assistance
Boston Industrial has provided and collaborated with Boston Scientific on over 25 projects in Manufacturing, Sterilization and Distribution sectors of the Supply Chain over the past 10 years.

BIC continues to extend their partnership in helping Boston Scientific improve operations and reduce costs worldwide.

Boston Industrial Consulting Expands Its Simulation Capabilities

2009-10-26T10:49:00.000-04:00

As business operations become more complex and diverse, the value of simulating a new process, equipment line change or conveyor layout proves to be beneficial. Through uniquely designed simulation, Boston Industrial is able to accurately predict and analyze the impact of new layouts or processes to provide clients with reliable information to make better decisions.

Simulation can be a powerful tool used throughout the decision making process.

Boston Industrial Consulting utilizes discrete event modeling software to analyze the operation as a whole, or perform a detailed analysis down to the individual SKU, location and person to provide an added level of accuracy and reliability.

Bluefin Hires BIC to Create its Expanded Manufacturing Operation!

2009-10-01T10:00:00.000-04:00

Boston Industrial Consulting (BIC), teaming with Jacobs Engineering Group, was recently selected by Bluefin Robotics Corporation to design its new Autonomous Underwater Vehicle (AUV) Assembly and Test Operation. The expanded operation will allow Bluefin to transition from a limited production job shop, to a mass manufacturing Lean based operation.

Since the award, BIC has worked closely with Jacobs and Bluefin to determine spatial and facility requirements, incorporating high growth with Lean Manufacturing techniques. Several proposed concepts of operation have been developed that will allow for more efficient production techniques to be incorporated into the manufacturing operation.

Currently working on detailed design, the team has focused on finding efficient means to use the selected site with more efficient handling and production techniques. New material handling equipment will be used to move heavier and larger products effectively through the Manufacturing and Testing operations. BIC is working with Jacobs and Bluefin throughout the Design, Construction and Implementation portion of the project.

Bluefin Robotics joins an ever-growing list of companies turning to BIC to achieve maximum efficiency and operational improvements.

About Bluefin Robotics...

Bluefin Robotics manufactures and develops Autonomous Underwater Vehicle (AUV) vehicles, systems, and technology. Founded in 1997, the Company has grown to become a world leader in AUV products designed for military, commercial (oil and gas exploration, sea floor mapping), archaeological and other applications. Bluefin Robotics is a wholly-owned subsidiary of the Battelle. For more information, visit www.bluefinrobotics.com or contact Deanna Abraham at (617) 715-7080 or at dabraham@bluefinrobotics.com.

BIC Helps Southwick Clothing Sew Up Operational Savings!

2009-04-30T14:11:00.000-04:00

Southwick Clothing LLC, a division of Brooks Brothers / Retail Brands, recently hired Boston Industrial Consulting to improve its efficiency and reduce its real estate burden within its Suit Manufacturing Operation. BIC has developed a new manufacturing layout and is in the process of implementing Southwick Clothing’s new State-of-the-Art Suit and Pant making facility at 20 Computer Drive in Haverhill, MA.

Southwick Clothing presently manufactures suits and pants in a 5-story operation on Canal Street in Lawrence, MA. Forced to move to a new location, Southwick Clothing, and its new parent Brooks Brothers, saw this as an opportunity to transform the operation into a more cost efficient and responsive Manufacturing center. Working closely with Southwick and Brooks Brothers personnel, Boston Industrial developed a more efficient spatial and operational layout, which will provide faster response time to retail outlets with increased automated production techniques. The elimination of WIP, improved work flow and a single-level manufacturing concept will allow Southwick to work in approximately half of its current square footage, and realize an increase in productivity by 25 – 35%.

Boston Industrial is currently helping Southwick and Brooks Brothers execute the plan, through on-site coordination of the many processes required to run new and existing equipment. The facility will use power, steam, air, vacuum, gas, and on-floor monitoring systems to run over $6M of new equipment and material handling systems. BIC will also assist in a smooth transition as Southwick moves from its current mill building to this State-of-the-Art facility in February 2009.

Boston Industrial Consulting continues to work with companies to help streamline their operation and increase profit margins! Our team’s work in this area has helped Boston Scientific, Edward’s Lifesciences and Caterpillar achieve similar savings.

We continue to look for new ways to help our clients in lower costs, increase productivity and maximize earning potential.

About BIC...

Founded in 1996, Boston Industrial Consulting, Inc. is celebrating its 12th 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 Drives VIP Parts, Tires and Service to Higher Level of Efficiency!

2009-04-30T14:10:00.001-04:00

VIP Parts, Tires and Service is New England's largest privately held automotive parts and accessories chain. Based in Lewiston, Maine, VIP operates 57 stores in Maine, New Hampshire and Massachusetts. VIP was founded in 1958, and merged with Quirk Tire to become one of the leading automotive distributors in New England.

VIP turned to BIC looking for help to optimize their Distribution operation by examining utilization of space, equipment, process, and technology. The critical focus was to optimize the efficiency and capacity of their operation, while maintaining their high level of service to their customers.

BIC's analysis revealed that a more efficient picking process could result in a 30% increase in productivity. BIC recommended changes to product slotting and storage of on-hand tire inventory to allow VIP to increase throughput by up to 20% while improving capacity by over 15%. As a result, VIP has the potential to realize shorter turn-around times and a more accurate inventory level. An implementation of the proposed systems will occur over the summer of 2009.

VIP's unique seasonality and diverse product base is an interesting distribution challenge. The wealth of data and willingness of employees to explore new ideas significantly aided in the success of the project. The anticipated impact of the proposed changes is indicative of VIP's dedication and desire for continued success and growth!

BIC continues to work with companies such as VIP, Subaru of New England and Caterpillar who desire continuous improvement throughout their operations and growth, even during these challenging economic times.

Federal Supply Schedule Contract to Boston Industrial Consulting, Inc.

2009-04-15T13:57:00.004-04:00

Boston Industrial Consulting, Inc., a leading provider of Industrial Engineering and Operations Management Consulting services is pleased to announce its award of a 5-year contract to the U.S. General Services Administration (GSA). BIC will focus on providing Operational Engineering services for Supply Chain projects, as well as Distribution, Warehousing and Material Handling programs. The contract allows Government Agencies to take advantage of BICs full portfolio of effective and practical solutions, experience personnel and unbiased solutions.

In order to achieve the GSA status, BIC underwent a strict conformance and selection process. BIC joins a limited group of providers in this service category; only companies with the highest level of customer satisfaction coupled with an effective cost structure are granted approval.

The successes of our past and current clients are a testimony to our capabilities. We invite you to join a list of satisfied client that include Tobyhanna Army Depot, 8 Caterpillar dealerships, Tiffany & Company and Boston Scientific Corporation.

BIC Design Maximizes Cleveland Brothers CAT Warehouse Efficiency!

2009-02-04T10:35:00.000-05:00

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.

BIC Guides Edwards Lifesciences towards World Class Manufacturing!!!!

2009-01-29T10:35:00.000-05:00

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!

2009-01-25T10:33:00.000-05:00

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

2009-01-24T10:31:00.000-05:00

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.

2009-01-23T10:31:00.000-05:00

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

2009-01-22T10:29:00.000-05:00

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 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

2009-01-21T10:28:00.000-05:00

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

2009-01-20T10:28:00.001-05:00

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!

2009-01-19T09:31:00.000-05:00

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!

2009-01-18T09:28:00.000-05:00

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...

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!

2009-01-17T09:46:00.000-05:00

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...

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!

2009-01-16T09:29:00.000-05:00

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...

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!

2009-01-09T15:05:00.001-05:00

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.

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.

Massachusetts Medical Society Seeks BIC’s Help

2008-02-24T10:03:00.000-05:00

Boston Industrial Consulting was contracted by Massachusetts Medical Society to perform an Operations Analysis on the current Print Shop Operations, and the effect on the business if migrated to a new location or a 3rd party operation.

A multi-phased approach was adopted where management interviews / surveys, data analysis (financial and operational) and process mapping were used to develop conclusions and recommendations presented to MMS for implementation.

An operational Analysis was performed, moving the consolidation of print / finishing services into a new expanded facility.

Detailed operating costs for the new Print Shop location (FY07) were estimated

One-time costs associated with a new location were determined

Production costs per unit was assembled for each work stream, sub-stream and specific quantity ranges

An analysis comparing In-house vs. Outsource printing costs was performed using vendor pricing and multiple options were reviewed

Recommended physical improvements for the Print Shop Operations were developed using industrial engineering process mapping techniques and analysis. A final detailed layout, MEP Requirements and formal project plan was developed.

BIC’s recommendations included:

Employing the use of visual aids to guide print shop personnel while performing their duties

Establishing more formal guidelines for customers

Explore the use of a scheduling tool to provide increased efficiency

Design a new more efficient print operation

The relocation of the operation and implementation of BIC’s recommendations facilitated a nearly seamless relocation and transition.

Boston Industrial Consulting assists companies such as Massachusetts Medical Society, Boston Scientific Corp. and Subaru of New England reduce costs and improve efficiency.

Subaru New England Hires BIC to Improve its Parts Depot

2008-02-22T11:09:00.000-05:00

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 a 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 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 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.

BIC Helps Vi-Jon Optimize its Supply Chain Strategy

2008-02-22T09:34:00.000-05:00

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.