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2. Identified Opportunities to
Increase Productivity
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• Updated designs for packaging and cell
layouts for high labor content products
• SR560M and other carts and Stands
• DS-VW765-LAND – Video Wall
• Dedicated cells to run shop orders with
optimal crew sizes

3. Redesigned Layout for Carts & Stands
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 Start of the Line: 1 Piece Carton
 Placed on Conveyor
 Components packed at tables
 Staples replace tape
 End of the Line: 1 Piece Carton  End of the Line: Pallet located next to
aisle for easy access by forklift

4. Projected Cost Savings
Redesigned Packaging and Layout for Carts
 Before Improvements:
 25 units/hour with a crew size of 7 people
 EAU = 7,136 units/year – 2,000 labor hours
 After Improvements:
 28 units/hour with a crew size of 6 people
 EAU = 7,136 units/year – 1,529 labor hours
 Total Labor Hours Saved = 471 hours
 Labor Rate = $42.14/hour
 Estimated Total Annual Savings = $ 19,850 4

5. Redesigned Packaging for Video Walls
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Carton is too deep –
requires extra filler paper
Inserts need to be folded
Adapter Brackets Wrapped in
Paper and then put into Carton
 Before Improvements:

6. Redesigned Packaging for Video Walls
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 After Improvement:
New Inserts for Adapter Brackets
Replaced Inserts with
Corner Protectors

7. Projected Cost Savings
Redesigned Packaging for Video Walls
Per Unit Per Year
(EAU=24K)
 Materials Savings = $1.55 $37,200
 Labor Savings = $2.95 $70,800
 Total Savings = $4.50 $108,000
Projected Annual Savings = $108,000
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8. Projected Cost Savings
Total Projected Labor Savings
 Video Walls – New Packaging $108,000
 Carts and Stands-New Layout $19,850
 Extension Columns-New Methods $9,615
 Total Projected Labor Savings $137,465
 Total Projected Materials Savings $37,200
Projected Annual Savings $174,665
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9. Projects In Process
Dedicated Cells to Utilize Optimal Crew Sizes
 Features:
 Shop Orders routed to specific cells based on Crew Size
 Cells are located across the aisle from staging areas
 Next Shop Order is setup prior to completion of current order
 Benefits
 Increases productivity since work load is balanced
 Scheduler schedules multiple orders
 Cell leader knows in advance the next orders to run
 Minimizes or eliminates downtime between orders

10. Cells with Dedicated Crew Sizes
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Cell C011 - Optimal Crew Size = 3

11. Projects In Process
Work Cell Floor and Table Layout Template
 Features:
 Shows Material Handlers where to place containers of parts
 Shows Cell Leaders and Workers:
 what parts are required for each work station
 where to place parts at the work stations
 Benefits
 Allows Material Handlers to perform part of the setup
 Locates parts close to point-of-use
 Minimizes travel distances between containers and stations
 Minimizes or eliminates downtime between orders

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Developing
Cell Floor &
Table Layout
Templates