Date of Submission
Industrial and Systems Engineering
Industrial and System Engineering
Our team undertook the task of creating a plan of improvement for the calcine warehouse at KaMin LLC in Macon, Georgia. After a thorough examination of the warehouse, it was clear that there were four clear issues present. The layout and organization were not up to standard, with different types of finished product being stored in the same area. Floorspace was not fully utilized and there was not always enough room to meet storage requirements. The use of signage and labeling was extremely inefficient, requiring up to two eight-hour workdays to complete inventory count. The utilization rate of Bagger Machine Number 7 was much lower than the other machines and the forklift operator had to take a much longer route to move finished product into the warehouse, creating a significant amount of wasted time and motion.
The results of the analysis showed that each proposed solution provided a sufficient improvement to the warehouse and justified the budgetary costs. The new labeling system and new loading dock location provide benefits in units of reduced time waste and reduced motion waste. Implementing the adjustable pallet rack system with the new layout provides an increase in max inventory capacity of 576 pallets (41% increase). If the calcine warehouse continues to move 80% of max inventory capacity on a weekly basis, this offers theoretical annual profits of $1,198,080.