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Throughput Analysis - Aluminum Plate Production

Reflecting on processes

Jackson County, West Virginia

With demand for aluminum plate outstripping production, a major aluminum products manufacturer turned to us for solutions that would increase throughput and provide a quick return on their investment. This confidential client commissioned a detailed throughput analysis of their plate production operations.

We started with a two-week site survey, observing their shop processes and practices, conducting numerous interviews, timing their processes, and collecting a large amount of data. After detailed analysis (considering production planning, process flow and capability, worker utilization, maintenance, downtime, material handling systems, and quality), we delivered a report that outlined our conclusions and recommended countermeasures, both short and long term.

The result? Our practical recommendations suggested a 34% increase in throughput, with payback periods between three and 15 months. 

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