A major Department of Defense (DOD) remanufacturing and repair facility for military vehicular equipment needed an improved method for tracking materials and reporting activities across a large industrial complex.
The challenge for this DOD facility was to determine how to achieve these operational and data visibility goals – without disrupting the productivity of 5000+ personnel. All of this needed to be accomplished as quickly as possible as the facility was facing an increased demand for performance driven by current world circumstances.
It was determined that by leveraging a uniquely configured solution, built on a commercially-available Warehouse Manufacturing System (WMS) and Manufacturing Execution System (MES) software platform, we could achieve the management control and visibility goals with the least disruption of the staff. By creating a solution that leveraged strategic capture of material movements, we could deliver not only the material visibility, but also harvest the needed work in process (WIP) data on task durations, rework requirements, completions, etc. critical for planning and reporting.
The success of the implementation allowed the initial site deployment to reduce their WIP inventory by over $500M and save thousands of labor hours annually. A version of this solution was later deployed to another DOD remanufacturing site with additional significant benefits.