Manufacturing Optimization: Pelican's BX255 Case

Presenter

Cleo Hein

Campus

UMass Amherst

Sponsor

Scott M. Auerbach, Integrated Concentration in Science (iCons) Program, UMass Amherst

Schedule

Session 2, 11:30 AM - 12:15 PM [Schedule by Time][Poster Grid for Time/Location]

Location

Poster Board A82, Campus Center Auditorium, Row 5 (A81-A100) [Poster Location Map]

Abstract

Pelican, an American multinational company, specializes in designing and manufacturing protective cases for various industries such as military, law enforcement, fire safety, and consumer entertainment. One of Pelican’s consumer cargo cases, the BX255 has an inadequate profit margin and has received customer complaints regarding its quality. The objective of this project is to optimize the manufacturing process of the BX255 by decreasing the build cost by 10% while enhancing product quality. To reduce build costs, this project employs a methodology centered on material and labor cost reduction. Material costs are addressed by comparing suppliers, restructuring ordering procedures, and optimizing supply chain and inventory costs. To facilitate labor cost reduction, Lean Manufacturing tools such as Operator Loading Charts, Process Flow Diagrams, Spaghetti Diagrams and Time Studies are used. These tools enable the identification of opportunities to streamline processes, reduce cycle times, enhance intuitive assembly techniques, minimize scrap rates, and address quality concerns. This methodology surrounding material and labor aims to enhance production efficiency and product quality while minimizing cost. The objective of this study is to provide specific recommendations to Pelican, detailing how to achieve the targeted 10% reduction in build cost. These recommendations will include simulations and data to illustrate implementation strategies. The recommendations from this project have the potential to significantly influence the broader manufacturing industry. By optimizing assembly processes, efficiency is improved, driving innovation and progress across industries. These recommendations establish a precedent for enhanced productivity and competitiveness, with the potential of optimizing manufacturing on a large scale.

Keywords

Manufacturing, Assembly, Optimization, Lean Manufacturing, Industrial Engineering

Research Area

Engineering

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