The following case study is based on a solved, real-life problem in a manufacturing company. The example is a fragment of the whole.
Problem: Unsatisfactory performance (low profit in relation to inputs)
Challenge: Is it possible to save PLN 1,000,000 per year in the production process without reducing efficiency?
In the case presented, the introduction of changes made it possible to achieve savings at the assumed level. The solutions proposed by BPI and applied in the company made it possible for one employee to work instead of two. It was possible to reduce the number of employees but we recommend that the employee should not be dismissed but transferred to a department where vacancies exist. Savings resulting from the presented substitutions amount to PLN 60,000, PLN 120,000 and PLN 180,000 per year for work on 1, 2 or 3 shifts respectively. At the same time, this case study shows a fragment of a larger production - only three positions/machines. Assuming that the production is composed of min. Assuming that production consists of at least 15 stands/machines, it will be possible to introduce changes and improvements resulting in savings of PLN 1,000,000 per year or more. per year or more. The presented example - a cut-out, is based on real production, in which the proposed savings exceed 1,000,000 PLN per year. Simulations were carried out using LogABS software, of which we are also a distributor.
Screenshot of the simulation:
Based on simulation 1, we obtained the following data. In the graph we can see the involvement of machines and workers in the activities:
Screenshot of the results:
Screenshot of machine repositioning - machines M1 and M2 were placed side by side:
Screenshot of results from simulation 3:
This case study presents one possible improvement of which Business, Progress, Innovation has many more.