Improvement of Material Handling Processes for High Volume Manufacturing

This paper presents an in-depth analysis of a material handling initiative implemented at a high-volume residential water meter manufacturing facility in the United States. Faced with challenges such as inefficient inventory levels and non-value-added material movements, the project team followed the DMAIC (Define, Measure, Analyze, Improve, Control) process to offer strategic recommendations aimed at decreasing time wasted waiting for parts and improving use satisfaction of the company's inventory management system.The project's focus centered on optimizing the handling of plastic parts produced in-house, specifically those that did not necessitate secondary processing. The objective was to streamline the flow of these components directly from the plastics production area to the manufacturing floor. This seamless transition aimed to facilitate the repurposing of a designated section within the warehouse. By implementing these measures, inventory control is optimized for increased efficiency and cost-effectiveness, allowing for the utilization of additional physical space within the facility. The comprehensive approach adopted in this initiative not only addresses immediate concerns but also provides the opportunity for further improvements in material handling processes, contributing to the overall operational excellence of the manufacturing facility.