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THE PROBLEM
CSC ServiceWorks faced challenges in their Atlanta refurbishment center, struggling with inefficiencies in refurbishing, packing, and shipping processes for field deployment. The facility lacked a streamlined flow, creating bottlenecks and limiting throughput. Additionally, ergonomic risks, underutilized inventory management, and inconsistent workstation designs were contributing to high labor costs and limited scalability.
KEY QUESTIONS
- How can CSC ServiceWorks increase throughput and efficiency in their refurbishment center?
- What solutions can improve workstation design to enhance flexibility and reduce ergonomic risks?
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How can inventory management and shipping processes be optimized to meet capacity demands?
- What phased implementation approach ensures minimal operational disruption during upgrades?
THE SOLUTION
Maveneer partnered with CSC ServiceWorks to design and implement a comprehensive solution tailored to meet the facility’s needs.
Process Optimization: Introduced standardized work processes and performance measurement systems to enforce quality expectations and minimize labor inefficiencies.
Universal Workstations: Designed flexible workstations with machine lifts and defined layouts to reduce ergonomic risks and enable scalability for future growth.
Improved Inventory Management:
- Consolidated parts into a centralized, controlled storage area to enhance visibility and tracking.
- Utilized point-of-use racks to reduce travel time for technicians.
Refurbishment Layout Redesign: Proposed a new layout to consolidate panel racking and refurbishment zones, improving workflow and enabling better forklift access.
Shipping and Storage Enhancements: Integrated single-layer machine shipping projects to simplify processes and increase branch participation, while recommending vertical storage to maximize space.
Implementation Schedule: Developed a phased implementation plan, allowing gradual integration of improvements within three months without disrupting ongoing operations.
KEY RESULTS & INSIGHTS
- Throughput Gains: Projected throughput increased significantly, with an immediate improvement identified to start realizing gains even before full implementation.
- Labor Efficiency: Standardized processes and ergonomic improvements reduced labor costs and cycle times, leading to sustainable cost savings.
- Scalable Workflows: Universal workstations and centralized inventory management created a flexible system that supports up to 60% future growth in workstation capacity.
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Quick Payback: The business case demonstrated a payback period of less than one year, with some benefits realized within the first month.
- Operational Transparency: Improved tracking and reporting systems provided greater visibility into refurbished inventory, enabling better decision-making and planning.
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