Manufacturing, Distribution and Trade Success Story

Assessing the Flow of Materials for an Industrial and Specialty Vehicles Manufacturer

The client is a leading manufacturer of rescue trucks, emergency vehicles, and military specialty vehicles. Their customers are predominantly government entities in the US.

The vehicles the client assembles have a high degree of customization and can require up to six months manufacturing. The sub-assemblies and major components are manufactured and shipped from different sites.
As the company grew, the material flows between manufacturing facilities and product lines grew more complex. The resulting flows led to delays in production, loss of inventory control, and numerous non-value-added activities.

The Revere Group was tasked with assessing the plant material flows. Revere consultants walked the production lines, interviewed staff, and assessed production management systems.
Several flow models were explored to improve production throughput and reduce work-in-process inventory. Different production planning models were also explored.
Revere developed a list of recommended actions and an implementation plan.
The plan was a phased approached that included Materials Resource Planning (MRP) and Batch Scheduling, Rescheduling, Material Flow and Handling, and Potential Baseline Metrics.