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Industry
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Manufacturing Logistics Consulting Projects
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Beverage
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- Evaluation of multiple automation vendors and automated material handling systems for a mega production facility to be operational in Saudi Arabia in 2014. Solutions evaluated include High Bay Warehouse (45m) ASRS cranes with dual pallet handling capability; stacker cranes with satellite shuttles for automated deep pallet storage; multi-level shuttle technology for high bay storage; overhead monorail systems; floor-mounted inverted monorail systems; automatic laser-guided vehicle systems; powered pallet conveyor systems, and automated truck loading systems.
- Development of detailed facility layout options for handling of raw materials and packaging supplies.
- Development of detailed specifications and RFP documents for mobile equipment and automated laser guided vehicle systems.
- Participation in the evaluation and selection for automation vendors.
- Complete implementation services including the development of equipment specifications and bid tender documents, shop floor CAD drawings, and participation in an international project involving multiple automation and engineering companies from different countries.
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Beverage
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Beverage
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- Distribution center design and master site planning for multiple options to reconfigure a NY-based wine distribution center and distribution network to enable the consolidation of multiple shipping operations and to reduce overall logistics expenses.
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Consumer Packaged Goods
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Food and Beverage
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- Performed a complete WMS solution evaluation and vendor selection study for a producer and DSD distributor of high quality chilled beverages and ice cream to the North American market.
- Conducted a detailed survey of existing warehousing operations and developed a complete set of formal documents to support the evaluation and selection of a new warehouse management system including a current operations document, vision document, and RFP document.
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Food and Beverage
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- Designed a major distribution center expansion and reset of existing space to enable an outdated storage facility to expand from 75,000 to 150,000 square feet of world class distribution space to support a doubling of the company's business revenue.
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Food
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- Distribution center design study involving the design of 8 different warehouse rack and aisle layout options for a campus of 4 production / warehouse buildings for a soup mix manufacturer in New Jersey.
- The project involved a warehouse expansion and reset of existing space in order to support the company's growth objectives. Proposed material handling systems included the use of Bendi very narrow aisle trucks combined with 2-deep, 3-deep and 4-deep push back racking systems to maximize storage capacity and labor efficiency.
- A subsequent project provided multiple facility layout options for a food-grade production plant/warehouse in Las Vegas, NV.
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Food
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- Extensive distribution operations assessment study performed for one of the largest food manufacturing companies in the world. Assessment involved two mixing centers totaling 2,100,000 sq. ft. to identify the operating expense savings associated with replacing a legacy Warehouse Management System (WMS) with a new best-of-breed application.
- Recommendations to improve labor efficiency through multiple warehouse layout and material handling changes.
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Food
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Food
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Food
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- Designed a 35,000 sq. ft. high-bay warehouse facility attached to a production facility for the handling and storage of raw materials and finished goods pallets for an organic egg producer in the Northeast USA.
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Food
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- Conducted a study to evaluate 8 different production / distribution facility expansion options to projected growth rates for a large hummus production facility in Colonial Heights, VA.
- Also developed a master site plan to handle increased truck traffic flow on the site.
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Food
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Food
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- Distribution center design and master site planning for multiple plant-warehouse expansion options to handle projected increases in shipping volumes.
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Food
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- Distribution center design and master site planning for a distribution center expansion to provide increased storage capacity to handle future growth projections.
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Food
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Food
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- Strategic master planning for the expansion of a meat producer's chilled warehouse attached to its main pork production facility.
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Food
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Food
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Food
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Food
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Automotive
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- Operational assessment for automation solutions to apply to a large parts distribution center in Sealy, TX .
- Operational assessment for automation solutions to apply to a large vehicle assembly plant in Houston, TX.
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Heating and Ventilation
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- Distribution network strategy for a leading manufacturer of chimney ventilation products to evaluate the addition of a new facility and a change in the role of existing facilities.
- Detailed operational assessment of distribution operations at three of the company's existing distribution operations in the United States and Canada.
- This project also identified specific opportunities to reduce operating expenses, change warehouse layouts and implement solutions to better manage emerging channels such as e-commerce.
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Industrial Machines
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- Conducted a distribution network strategy assessment for the domestic and export distribution operations for a company that designs and manufactures the world's most advanced plasma cutting systems for use in a variety of industries such as shipbuilding, manufacturing, and automotive repair.
- Designed multiple logistics centers as part of the mandate. Full blown implementation of a new logistics center including detailed equipment specifications, working with architectural and engineering firms to modify an existing building, bin numbering, labeling, final slotting and transition to the new building.
- Detailed review of Oracle WMS functionality and technical issues to support all defined process flows within the new logistics center.
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Industrial Machines
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- Conducted an operational assessment for a manufacturer of precision tooling machines at a 1.2 Million sq. ft. manufacturing and distribution campus to provide recommendations on automation opportunities.
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Industrial Supplies
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- Conducted a WMS solution and vendor evaluation study for a $1 Billion manufacturer of industrial components for the electrical and utilities network.
- The study also involved a strategic assessment of supply chain strategy decisions.
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Industrial Supplies
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- Designed multiple options to introduce a new centralized logistics center in Petersburg, VA for a manufacturer of industrial components serving the railroad, vehicular, and construction and building markets. Facility design concepts included very narrow aisles and the use of Drexel turret trucks.
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Industrial Supplies
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- Distribution network strategy for 10 years for a global manufacturer of industrial supplies. Study evaluated multiple facility location options for logistics operations to support domestic and global operations. Five facility design options were provided to enable realistic capital investment requirements for each option.
- Detailed design of a new 35,000 square foot logistics center for national distribution to support six sigma and lean manufacturing operations
- Complete implementation services including the development of equipment specifications and bid tender documents, shop floor CAD drawings, and participation in vendor evaluation process.
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Industrial Supplies
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- Operational assessment to improve packing and shipping operations at a production plant in Paramus, NJ.
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Home Fitness Equipment
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- Conducted a facility master planning study for a 475,000 sq. ft. distribution center in Columbus, OH to improve the storage capacity of the facility with the goal being to enable the consolidation of multiple operations.
- A subsequent study was conducted to enable the consolidation of parts distribution into this same facility.
- Performed a subsequent second mandate to consolidate parts distribution from 2 locations into one distribution center. Project involved the detailed design of the parts storage and distribution operation.
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Footwear
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- Conducted a strategic strategy to help a $500M sporting shoe company understand the economics of expanding their distribution network in North America.
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Tobacco
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Musical Instruments
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- Supply chain strategy study to optimize global distribution operations that includes product sourcing from Peru, Thailand, Taiwan and India for a Canadian-based manufacturer of musical instruments.
- Study evaluated the relocation and consolidation of two warehouse operations to reduce operating expenses.
- Also conducted a distribution strategy to study to evaluate optimal distribution strategies for the European market.
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Health Care
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- Design of a 60,000 sq. ft. automated distribution facility expansion with 11 different layout options depicting automated storage and case handling for raw materials, packaging supplies and finished goods up to 44’ clear stacking height.
- Options included the use of very narrow aisle turret trucks, span track selection racks, and the latest in automated case picking technologies using multiple ASRS mini-load case extractor machines that enable cases to be stored 4-deep and then automatically extracted / picked with no human intervention.
- Facility expansion design enabled 8 years of growth by positioning production operations for delayed product packaging operations on 3 levels of mezzanine positioned over the main receiving / shipping dock.
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Pharmaceuticals
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- Distribution network strategy study to enable the consolidation of multiple third party distribution centers into a consolidated facility.
- Distribution center design and master site planning for a reset distribution center to enable consolidation.
- Implementation of facility changeover.
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Chemicals Manufacturing
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- Evaluated outbound transportation operations at air separation plants and compressed gas fill plants for a producer and distributor of cryogenic and compressed gases, welding, safety, and medical supplies with over 70 branches in the Western USA.
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Packaging Manufacturing
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- Distribution operations assessment to evaluate options to reduce the manufacturing plant's reliance on 150,000 sq. ft. of outside storage space to store raw materials, finished goods and printing cylinders for a major manufacturer of food-grade packaging materials based in Morristown, TN.
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Jewelry
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Office Supplies / Paper
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