Services
Capacity Analysis and Operational Assessment
Design automated sortation and material handling systems layouts, from concept design, 3D modelling to complete integrated solution.
Data analysis and capacity evaluation.
Throughput analysis and operational capability studies.
Future demand forecasting and operational sizing.
Evaluate current capacities and operational capabilities.
Analyze throughput and performance of existing systems.
Identify improvement opportunities.
Sizing Studies and Facility Planning
Assess space requirements to support future business growth and meet new capacity needs.
Assess future demand against existing system capacity.
Calculate facility size requirements for future operations.
Recommend equipment types, quantities, and specifications.
Recommend equipment types, quantities, and specifications.
Facility and System Design
Comprehensive facility designs with optimized operations, efficient space allocation, and seamless workflows for greenfield or brownfield sites.
Facility layouts and redesigns for warehouses, airports, and manufacturing sites.
Equipment specification and selection.
Zone planning, access points, and staffing requirements.
Create layouts or redesign facilities, including operational zones and access points.
Plan equipment selection, such as conveyors, racking systems, and automation components.
Develop facility plans for warehouses, airports, and manufacturing sites.
Automation and Sortation Solutions
Design automated sortation and material handling systems layouts, from concept design, 3D modelling to complete integrated solution.
Design and implementation of automated sortation systems for logistics, airports, and manufacturing.
3D modeling and digital twin creation.
Feasibility studies, peer reviews, and SOP development.
Design and implement automated sortation and material handling systems.
Generate 3D models and digital twins for precise visualization.
Conduct feasibility studies, peer reviews, and SOP development.
Simulation and System Performance Testing
Simulate and test system performance to assess feasibility, optimize processes, and ensure peak efficiency under various operational scenarios and demands.
Process simulations for material and baggage handling systems.
Testing solutions for feasibility under peak and stress conditions.
Equipment utilization and operational scenario analysis across industries.
Simulate processes to test solution feasibility and performance.
Assess system performance under peak demand and stress conditions.
Analyze equipment utilization and operational scenarios.
Process Optimization and Lean Solutions
Streamline operations, implement lean solutions to reduce waste, non-value-added processes, improve efficiency, innovation and enhance overall system performance.
Reducing bottlenecks and maximizing infrastructure efficiency.
Lean manufacturing solutions, time studies, and non-value-added process elimination.
Optimization of layouts, designs, and operations.
Diagnose weak points, bottlenecks, and areas prone to breakdowns in existing systems.
Enhance efficiency, resilience, and redundancy of equipment, processes, and operations.
Provide tailored solutions, including system upgrades, renovations, or process redesigns.
Case Studies
Case Study: Production Line Optimization
Context:
An automotive assembly line with 50 workers, each performing a specific set of tasks in sequence. The line was already relatively efficient; however, the introduction of new vehicle models required task reallocation to accommodate the new assembly requirements while maintaining or reducing the tack time. The goal was to reorganize tasks to ensure that the new models could be assembled efficiently, with equal worker utilization and high quality.
Approach:
Assessment:
- Evaluated existing processes, technologies, and workflows.
- Conducted a time study of tasks for both existing and new vehicle models.
- Identified tasks specific to the new models, along with technology and other requirements.
Data Analysis and Planning:
- Gathered and analyzed task data to identify bottlenecks and inefficiencies.
- Reorganized all tasks in a chronological sequence, considering spatial constraints and dependencies.
- Eliminated non-value-added activities.
Optimization:
- Adjusted task allocations to accommodate new vehicle models while balancing workloads.
- Optimized the workspace and reviewed ergonomics to enhance worker efficiency.
Results:
- Tack time was reduced from 3 minutes to 2.5 minutes for all 50 workers.
- The production line achieved full utilization of workers while maintaining high-quality standards.
- Increased capacity allowed for smoother integration of new vehicle models, reducing assembly costs per vehicle.
Business impact
Improvements achieved
CASE STUDY - Optimizing Manual Sortation Postal Business
Background
This project focused on improving the manual sortation process for imported shipments in the Express Postal business. Shipments arrived in airline containers, were transported to the logistics center, screened, and moved via conveyors to a sorting area where 6 sorters worked manually for five hours per cycle. This process occurred twice daily, leading to inefficiencies and high labor costs.
Challenges
Key issues included:
- Inefficient Layout: Scattered cages caused confusion and wasted time.
- Excessive Walking: Sorters spent significant time moving between cages.
- Lack of Standardization: Tasks were unclear, and processes were inconsistent.
Optimization Process
- Task Allocation: Assigned sorters specific zones or postcodes and grouped cages by destinations.
- Standardized Layout: Redesigned cage placement to reduce walking and improve workflow consistency.
- Process Efficiency: Eliminated non-value-adding steps and streamlined operations from offloading to final sorting.
Results
The improvements reduced sortation time from 5 hours to 30 minutes per cycle, for 6 people, saving significant labor hours. Employees were freed to perform other tasks, and consistency in processes minimized errors and increased productivity.
Business impact
Improvements achieved
CASE STUDY - Sizing Study and Facility Design & Delivery
Context:
Due to significant business growth, the company needed to relocate to a larger warehouse. A decision was made to build a new, bespoke facility capable of accommodating the company’s operational needs and growth projections for the next 10 years.
Scope of Work:
Sizing Study:
- Conducted future growth analysis to predict operational requirements.
- Assessed processes, equipment, staffing, and storage needs to determine the facility’s and office building’s required size.
- Identified opportunities for optimization to maximize efficiency and future scalability.
Warehouse and Facility Design:
- Designed a bespoke warehouse layout tailored to the company’s needs.
- Developed a Material Handling System (MHS) design, including:
- Cargo systems for managing air containers.
- Loading/unloading platforms and scissor lifts.
- Properly sized gates to optimize workflow and traffic flow.
- Incorporated screening processes, as well as scanning, weighing, and packing equipment.
- Designed storage solutions, workstations, and safety features, including maintenance paths and egress routes.
- Planned and designed control systems for the MHS, including:
- Low-level and high-level controls for managing automated systems.
- Electrical designs and PLC system functionality.
Approvals and Procurement:
- Secured approvals from relevant authorities for the proposed designs.
- Assisted in the procurement of the entire distribution center solution, including suppliers for:
- MHS equipment.
- Cargo handling systems.
- Racking and storage systems.
- Other essential equipment.
Project Management:
- Oversaw the detailed design of MHS, cargo, and storage systems.
- Managed the delivery and implementation of these components.
Results:
- Successfully delivered the facility on time and within budget.
- Conducted comprehensive testing of all systems, ensuring they met operational requirements and quality standards.
- Provided a scalable and efficient warehouse capable of supporting the company’s growth for the next decade.
Business impact
Improvements achieved
CASE STUDY - Automation and Sortation Solutions for Airport
Context:
Faced with increasing passenger volumes and a projected baggage demand over the next 20 years, the airport required a comprehensive assessment of its baggage handling system (BHS). The goal was to provide two design solutions:
- A cutting-edge, fully automated system leveraging the latest technology to ensure long-term scalability and efficiency.
- An optimized solution for the existing BHS to meet projected demand while minimizing infrastructure changes and costs.
Both designs aimed to streamline operations, increase capacity, and improve system throughput while maintaining compliance.
Scope of Work:
Assessment and Forecasting:
- Conducted a detailed evaluation of the existing BHS, including control systems, equipment, and processes.
- Reviewed operational workflows to identify inefficiencies and opportunities for optimization.
- Analyzed baggage demand forecasts to determine future system capacity requirements.
System Redesign:
- Proposed two distinct solutions:
- Cutting-edge automated solution:
- Fully automated system with advanced sortation, Early Bag Stores, screening, batching systems, etc.
- Optimized existing system:
- The solution design with improved throughput and efficiency through automation and process enhancements.
- Cutting-edge automated solution:
- Proposed two distinct solutions:
Design and Specification:
- Delivered a 30% design package for both options, including layouts, flow diagrams, and key design elements.
- Provided system specifications for tendering purposes and future development.
Results:
- The cutting-edge solution offered a future-proof, high-capacity system with the latest technology, ensuring scalability.
- The optimized design demonstrated how the existing system could be adapted to handle projected demand while improving throughput and minimizing costs.