Bottlenecks Breakthroughs: How Automation Transformed Productivity & Morale

Identifying the Challenge

Recently, a medical device manufacturing customer of Abel Womack was interested in streamlining some systems processes. One of their priorities was to trim the fat while boosting production. They mentioned a few key goals discussed in a recent meeting, including:

• Increasing production
• Improving employee morale
• Reducing shipping delays to customers

The customer began by meeting with management teams in warehousing, shipping, receiving, and production. Annual employee reviews highlighted key issues impacting efficiency:

• Excessive time off during peak periods
• Poor communication about issues
• Extended breaks during critical deadlines

The second step was to review the information presented; some of this data came with no surprise. Employee feedback also revealed concerns about:

• Limited growth opportunities and stagnant pay
• Overly complex processes in some departments
• Frustrating bottlenecks between teams

Spotting Bottlenecks: A Key Discovery

Upon reviewing the data, the customer identified a major bottleneck. Finished goods were moving efficiently from production, but packing could not keep pace. One employee was juggling both packing duties and operating a forklift to move pallets, delaying the entire workflow.

Employee turnover in this role worsened the problem, as the position was viewed as unappealing and stressful.

Crafting the Solution through Collaboration

Abel Womack partnered with the customer to address these issues by:

• Identifying employees suitable for repurposing into new roles
• Calculating employee costs to ensure a positive ROI
• Conducting time studies to optimize workflow and reduce shipping delays

Implementing Change: Automation and Workforce Optimization

Our solution combined staff adjustments with automation. We introduced one employee to pack for two lanes. The shipping department took over pallet put away to streamline tasks. Finally, an automated conveyor and UR cobot was implemented to speed up label placement and palletizing efforts. This solution improved efficiency while repurposing employees to better-suited roles.

The Results: Faster Output and Immediate ROI

The impact was immediate. The company achieved a return on investment of $1,368.00 per month, starting on day one, using a 5-year financing plan. This solution increased production, and improved employee morale, and allowed for cost savings without impacting financial stability.

If your organization faces similar challenges, reach out to Abel Womack to explore tailored solutions and automation that drive results.