System Throughput Analysis

Background

A dental appliance manufacturer needed to increase production in one of their plant in Mexico. One part of their manufacturing process consisted of 13 robotic systems used for trimming their product. They believed that this area would be the bottleneck to achieving the new required production volumes, and as a result they contacted their system integrator to initiate the purchase of one more robotic trimming system.

AMT Engagement

As luck would have it, an AMT engineer was already working at their corporate headquarters in California. Although he was doing custom software development for a different part of their manufacturing process, when discussing the plans for expanding capacity in Mexico and installing a new robotic trimming cell, he realized that AMT had more to offer this dental appliance manufacturer. Knowledgeable of the expertise and ingenuity of our team, the engineer suggested that the manufacturer allow AMT to perform a throughput analysis on their existing system before they made any purchases of new equipment.

In the past, AMT has been known to save our clients millions of dollars on what would have been unnecessary expenditures by recognizing problems and optimizing systems and budgets. As much as $3 million has been saved as a direct result of AMT’s experience and knowledge. Developing a manufacturing process or generating specifications is contingent upon a thorough understanding of our clients’ strengths, weaknesses, goals, and limitations. We take a personal interest in the success of our clients’ endeavors, and this quality translates effortlessly into meticulous work and comprehensive research.

To this extent, AMT used software simulation tools to model the manufacturing process that the dental appliance manufacturer was currently employing. We were able to identify that in fact the 13 robotic trimming stations would not be the bottleneck to increasing throughput after all. Instead, because of incorrect product routing software in the conveyor system, one of the 13 robot systems was virtually unused. Therefore, this result meant that it would be entirely unnecessary for the dental appliance manufacturer to purchase yet another robot for their trimming system and that they could continue expanding production as they had previously planned.

Afterward

AMT was pleased to help the dental appliance manufacturer make the necessary changes to their conveyor software. In the end, they were able to achieve the increased throughput they desired for their plant in Mexico without purchasing a new robotic trim system. Based on their estimate, the AMT engagement saved them approximately $350,000.