high mix manufacturing

Manufacturing and Operations Strategy Consultants

Harmonic, Inc.

 DEHART CONSULTING, INC., working hand-in-hand with our factory personnel, redesigned our manufacturing areas and material flows to enable a 250% growth in output with only a 70% increase in floor space. Additionally, the changes were documented, implemented, and provided a clear path for future expansion. 


Mike Yost, Vice President, Operations Harmonic, Inc.

Lockheed Martin SB Focal Plane

Manufacturing Facility Design | Goleta, CA

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Project
Manufacturing Fabrication & Assembly

Location
Goleta, California

Project Type
Industrial

Project Size
240,000 sf

Project Duration
Design – 6-months
Build – 9-months

LM-SBFP is a world-wide leader in the design and fabrication of defense and aerospace components and was tasked with doubling its production throughput within its existing manufacturing footprint. DCI was hired to redesign the factory layout within the context of lean manufacturing principles and to assure the overall capacity increase.

The high-mix production environment involved a broad range of processes and products. DCI analyzed the value chain and reworked the facility layout delivering a 3x reduction in production span and the needed 2x increase in capacity.

A novel technology for demand-pull production was proposed to minimize floorspace dedicated to work-in-process inventory. Design Engineering, Facilities, and Operations Management staff we part of the team that assured the designs met the needs of all involved.

The design won the approval of corporate management and was implemented over a 2-year period.

Services

  • Lean Manufacturing
  • Facility Design
  • Construction Oversight

Vendor Coordination

  • Production Equipment
  • Information Technologies
  • ESD Facilitation

XILINX, Inc. AsiaPac Headquarters

Manufacturing Facility Design | San Jose, CA | Singapore

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Project
Manufacturing, Engineering, & Distribution Center

Location
Changi Business Park, Singapore

Project Type
Industrial

Project Size
290,655 sf

Project Duration
18 months

Xilinx Inc is the leader in programmable logic devices with 50% of the world market share. In the brief to DCI, space efficiency and sustainability was a core design consideration.

The warehouse is designed with automation in mind with direct material handling conduits to the production floor. Smart features such as air flushing, light management system and intelligent environmental features provide a productive working environment.

Tasked to ensure the incorporation of worldwide demand projections to Xilinx’s headquarters, DCI proposed features that enabled a mere 1.1% increase in construction investment but reaps an expected $500,000 savings each year.  DCI was responsible for analyzing production rates and capacity to assure that the resulting design was capable of meeting the needs of the 5-year forecast.

The project was awarded Platinum Green Award by Building & Construction Authority of Singapore, the first ever for a privately developed industrial facility.

Services

  • Facility Design
  • Construction Oversight

Vendor Coordination

  • Production Equipment
  • Warehouse Automation
  • ESD Facilitation
  • Security

CalAmp

Operational Supply Chain Design | Oxnard, CA

Calamp Dehart

 

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Project
Supply Chain & Manufacturing

Location
Oxnard, CA

Project Type
Industrial Profit Improvement

Project Size
150,000 sf

Project Duration
Design – 6-months
Conversion – 18-months

CalAmp is a technology company that specializes in telematics hardware and software and was struggling with high costs and an inefficient factory. DCI was engaged to assist in restructuring the Supply Chain, Physical, and Organizational design of the company to improve its performance and profitability.

The factory was redesigned into customer-focused modular teams along with all associated capital equipment. The Supply Chain was re-organized into major commodity bundles, contracts renegotiated in a Liability-limiting, highly flexible procurement framework, and overall material costs were reduced by 35%. Demand-pull logistical technologies were implemented in the factory execution systems, reducing WIP and FG levels by 60%. New Product Introduction teams were developed reduce time-to market and customer satisfaction.

The company’s operations were successfully turned around and profitability rapidly improved. The company's stock moved from less than $2 per share to over $45 per share within 2 years of its transformation.

Services

  • Lean Manufacturing
  • Facility Design
  • Supply Chain Strategy

Vendor Coordination

  • Production Capital Equipment
  • Information Technologies
  • Direct Material Suppliers

Pure Fishing

Manufacturing Facility Design | Spirit Lake, IA

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Project
Operations, Manufacturing Fabrication & Assembly

Location
Spirit Lake, IA

Project Type
Industrial

Project Size
300,000 sf

Project Duration
Design – 6-months
Conversion – 9-months

Pure Fishing is an 80-year old company with storied brands such as Berkeley baits and Abu-Garcia reels and was struggling to keep up with the demands of world-class customers such as Walmart. The company was generating obsolete inventory and not meeting its customers’ On-Time Delivery expectations

DCI was engaged to assist in the physical and organizational transformation of the company into highly focused, high-volume, factories based on Lean Manufacturing Methods.

The factory was divided into individual business units with operational KPIs and customer-focused organization structures, and then physically redesigned to meet its externally-focused demands for line, bait, rods, and reels.

The company’s operations were successfully turned around and profitability rapidly improved. It later attracted a $1.3B investment from a Private Equity firm.

Services

  • Lean Manufacturing
  • Facility Design
  • Construction Oversight

Harmonic, Inc. Amplifier Manufacturing

Facility Design | Lean Conversion | San Jose, CA

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Project
Lean Manufacturing, Facility Design

Location
San Jose, CA

Project Type
Industrial

Project Size
30,000 sf

Project Duration
12 months

Harmonic is leading the transformation for video, cable and media companies, with smarter, faster, and simpler solutions. Increased demand resulted in order high backlogs and longer production cycle-times that DCI addressed with Demand-pull production technologies.

  • Modular manufacturing facility design maximized flexibility for future changes
  • Production rate and capacity analysis-driven design
  • Point-of-use inventory storage with auto-replenishment
  • Dock-to-stock supplier awards to improve efficiency.
  • 30% reduction in material costs with improved strategic procurement methods.
  • Design met the needs of the 5-year forecast.
  • 2x increase in capacity and inventory turns.

Services

  • Facility Design
  • Construction Oversight
  • Supply Chain Strategy

Vendor Coordination

  • Architects
  • Construction Trades
  • ESD Facilitation
  • Raw Material Suppliers

Fujitsu, Inc. Foundry Supply Chain

Supply Chain Development | San Jose, CA | Torrance, CA

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Project
Manufacturing, Supply Chain

Location
California

Project Type
Industrial

Project Duration
18 months

Fujitsu, Inc is an industry powerhouse in the technology sector and came to DCI to develop and implement a supply chain strategy for its North American subsidiary.

  • Strategic supplier strategy developed and implemented
  • Procurement contracts developed and negotiated with key suppliers
  • Integrated the development resources in Japan and the US
  • Implemented a program management approach to foundry development and production management
  • Successfully transferred technology from Japan to the US subsidiary and foundry partner
  • Implemented a forecast-release logistics model to minimize inventories and liability
  • Products were introduced to the US market on schedules and under-budget

Services

  • Supply Chain Strategy Development
  • Program Management

Vendor Coordination

  • Foundry services
  • Logistics partners

Waymo

Warehouse conversion | San Francisco, CA

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Project
Convert former 32,000 sq ft trucking warehouse to fleet tech service garage

Location
San Francisco, California

Project Type
Industrial

Project Size
32,000 sf

Project Duration
18 months

Avison Young and DeHart Consulting partnered to provide construction management and industrial engineering services for Waymo.

32,000 sf warehouse converted to a fleet tech service garage, with:

  • 15 service bays, complete with lifts, alignment and balancing machines and exhaust system.
  • Service area workstations and work benches, new restrooms and shower, new pantry
  • Secure parts and storage cages, with shipping and receiving bay
  • 1 interior EV charger
  • Office space with conference room, micro kitchen, expanded electrical closet
  • Phase 2 involved replacing ADA lift with ADA compliant ramp.

Services

  • Facility Design
  • Capacity requirements planning
  • Traffic flow optimization

Vendor Coordination

  • Production Equipment
  • Information Technologies
  • Architect Interface