Brazilian cosmetics company, known for its global presence in over 50 countries, has the mission of promoting beauty and well-being through innovative and sustainable products. The company integrates the entire production chain, from laboratory development to distribution, and is a benchmark in quality and efficiency. With the growth in demand and the need for expansion, the organization sought to optimize its manufacturing and logistics processes to increase its production capacity.
By digitizing its processes, the company realized the need to increase transparency into the causes of known problems, increase efficiency, and gain a clear view of the interconnections between process areas. In addition, it was essential to study the impact of failures in critical equipment and understand the adaptations or investments needed to ensure continued operation.
Solutions:
Given this scenario, the company established a strategic partnership with EYF to implement solutions that would allow for precise planning of operations and the projection of different layout, storage and production scenarios. A solution was developed for the company’s first site, covering everything from pallet handling to product manufacturing and packaging. After completing this initial project, the company expanded the use of the solution to its second site, further optimizing its logistics and production operations.
- Site Planning 1: The first stage of the project consisted of creating a detailed digital plan for internal logistics, integrating storage, movement and production. The objective was to understand how the current layout impacted pallet movement and the capacity of freight elevators. Additionally, a resource was developed to determine the headcount required for each production line, taking into account the specificities of each SKU.
Results site 1:
- Possibility of increasing production by 59%
- 87% reduction in the volume of manually palletized boxes.
- 62% reduction in pallet separation time.
- Better use of freight elevators, eliminating idleness.
- Layout projections optimized for the use of AGVs (automated guided vehicles).
- Site 2 Planning: Following the success of the first project, a second phase was carried out for the company’s second site. The solution encompassed logistics as well as manufacturing and packaging processes. This made it possible to plan the insertion of new production lines, test different layouts, and propose solutions to accommodate the increase in demand.
Results site 2:
- Possibility of increasing production by 57% on the bottling lines.
- Significant increase in production with changes only in work regimes.
- Layout tests have indicated that a new machine could reduce overutilization of freight elevators.
- Truck flow: In an additional step, the company partnered with EYF to optimize truck flow, considering the expected increase in demand over the next 10 years. The proposed solution enabled a significant reduction in truck allocation time and a decrease in the number of internal parking spaces, freeing up more area for factory expansion.
Truck flow results:
- Demand for trucks is expected to increase by 53% by 2032.
- 57% reduction in the number of internal truck parking spaces.
- 62% reduction in truck allocation time in the receiving flow.
- 74% reduction in allocation time in the shipping flow.
Impact:
The project’s completion provided the company with a powerful solution to improve its operational management, based on detailed analyses and scenario forecasts. By enabling the evaluation of various short and long-term strategies, the company was able to anticipate the impacts of potential changes and increase its decision-making confidence.