PLANT MATERIAL FLOW

Thailand

Sector

FMCG


Issue

A manufacturer of health care products, exporting to 20 countries, was reaching the limits of a regional plant’s production and handling capacity, causing operational slow downs and necessitating the rental of multiple off-site warehouses


Solution

Conduct an end to end study: From raw-material suppliers through manufacturing and external storage to overseas shipments required to meet the needs of the global supply streams served by the plant

Identify options and refine (through a series of client challenge sessions and workshops) down to a single sustainable solution incorporating:

  • An increase in factory production floor and on-site storage capacity
  • An increase in on-site co-pack operations
  • Elimination of external warehouse storage for finished goods
  • Reduced touch finished goods handling (production line direct into ocean container)
  • Associated developments required in clientt’ ERP configuration

Results

  • 300 Sqm additional space released for production purposes
  • 6,000 additional pallet positions
  • 900 SqM Co-pack area
  • 100% elimination of external storage with 24 month’s payback
  • Release of 600,000 US$ cash
  • Maximum daily output increased by 33%