Process Improvement at a Major Bottling Company

The intent of this project was to study the process flow of products at a Major Bottling Company (MBC) and improve upon it. The process was studied from production to consumption and most aspects of the process were analyzed using techniques learned from Industrial Engineering courses. At the demand stage, the forecast for several specific product and package types was examined and recreated. The newly created forecast improves upon the provided forecast by being much more accurate. The production stage could not be closely analyzed because production takes place at different facility and is operated by a different group. The shipment stage was analyzed and a best shipping method was determined. From there the product interaction at the warehouse was examined and the warehouse layout was improved upon. The yard layout was adjusted such that more space was created and savings were made for reducing wasted time. A portion of the warehouse was analyzed and a recycling plan was implemented. Inside the warehouse, human interaction with forklifts and pallet jacks was also analyzed and a determination was made that most of the damage on the material handling equipment was caused by neglect and carelessness. The implementation of ShockWatch hardware was recommended to the facility and the safety and economic benefits were presented. In the end the entire process was improved and money was saved. Additional benefits also include environmental benefits as well as safety benefits.