Plant Logistics

Context

While working at Molex as a process simulation engineer, I led the simulation of plant logistics to improve 5S, evaluate future operating scenarios, and drive cost savings.

Some project details have been removed due to confidentiality.

Project Overview

The task was to identify the space required to safely and efficiently operate plant logistics processes. Proposed changes were evaluated in the simulation model and presented to company leadership.

The following areas were considered:

• Material flow across the plant
• Warehousing processes with inbound and outbound orders
• Operators and AGVs
• Packaging processes and WIP in the plant

Production and warehouse data were collected from SAP based on previous production orders. Future order scenarios were also considered as an opportunity to improve the current system.

The scope was broad, so each concern area was analyzed and presented to the appropriate stakeholder group. Warehouse improvements were reviewed with the warehouse management team, automation recommendations were reviewed with the automation team, and other proposals were reviewed with the relevant plant stakeholders.

Reviewed proposals included:

• New warehouse layout versus old layout
• Conveyor systems versus elevator systems
• Packaging process automation and plant location
• AGV implementation feasibility and fleet sizing in specific areas

Results

Several major plant improvements were approved for implementation by the plant manager. Simulation results supported the DFMA report and helped avoid physical testing of ineffective systems. The simulation provided a lower-risk way to evaluate plant changes and helped drive cost savings.