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THE PROBLEM
The global armored carrier, Brink's, had numerous facilities throughout their network. Some of the facilities had recently implemented high speed, fully automated processing equipment to reduce labor. However, the machines were highly dependent on large batches of work and sensitive to batch changeover times, limiting the returns realized from the investment.
These facilities, along with manually operated versions, were wrought with poorly configured layouts and inefficient process designs. A lack of consistent process design across facilities and poor operational discipline further hindered the ability to realize gains from automation.
KEY QUESTIONS
- What is the best flow and layout for the operation and how can it be standardized and scaled across 150+ facilities?
- How can existing equipment be better utilized?
- Is there a business case for further investment in automation and if so, what automation should be deployed?
- When and how?
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THE SOLUTION
Redesigned receiving processes and implemented a buffering process that enabled workers to accurately identify inbound deposits and map them to customer-specific service level requirements.
Specialized workstations were designed and 3D-modeled to optimize workflows by eliminating wasted time caused by a lack of necessary tools and staging space to process deposits.
Radically reengineered process flows and reconfigured the room layout to improve efficiency.
Outlined strategic inventory management changes, allowing the client to bypass an assumed constraint that had significantly throttled operations.
KEY RESULTS & INSIGHTS
- ~20% labor savings achieved across a 150+ facility network.
- Touches per deposit reduced by ~50%.
- Batch changeover time for automated machines completely eliminated by designing a new concurrent inventory processing model.
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