Wooden furniture manufacturer
Layout optimization: 14% lower department costs
A mid-size maker of high-quality wooden furniture, on the market for over 20 years. Raw wood is cut on a circular saw, machined on CNC machines and assembled by hand at assembly stations, with quality checks throughout.
14%
lower department costs
PLN 300,000
less working capital
1.5
fewer full-time positions in direct labor
Task
Improve the production and warehouse layout, which no longer matched the production. The variety of products slowed the flow of material and information, and the lack of buffers for materials and finished products made production less flexible and more prone to delays.
Work
What was done
- Built a digital twin of the current production and warehouse layout and simulated the material flow.
- Used AI to find the areas that needed optimization and to propose new layouts.
- Specialists chose the layout that fitted the company's possibilities.
- Simulated the chosen layout variant in the DBR77 digital twin.
Results
Results and benefits
Results
- Working capital went down by PLN 300,000 after the buffer was removed.
- Department costs went down by 14%.
- Direct labor went down by 1.5 full-time positions.
Benefits
- Mapping the production area took several days. The AI-supported optimization steps after that took seconds.
- The company can adapt faster when market requirements change.
The facts and numbers come from the case study published on dbr77.com. Read the original
Video
The case study on video
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