Automotive Storage Analysis

The Challenge

Storage Analysis for All Truck Models in Plant

The focus of this project was to conduct a storage analysis and develop a storage model for all the parts used in different models of trucks of a major Original Equipment Manufacturer (OEM).

The biggest challenge of the project was the unavailability of reliable inventory data with many variations of parts for low production truck models but very few common parts for all truck models. To add to the complexity, the common parts had high usage variation for different models.

DSI was tasked to evaluate the ‘current’ state, develop the storage strategy and conduct a storage analysis to come up with space requirement for storage of parts in the plant.

The Solution

Map the current state storage.
Develop the assumptions list for the storage analysis.
Define the methodology for carrying out the calculations for the space requirement.
Calculate the space and shelving requirements for each storage area.

The DSI Difference

The build and inventory data was collected and organized.
A list of assumptions was used for storage analysis due to lack of sufficient inventory data.
Storage locations were identified and mapped.
Based on the shelving requirement calculations, approximately 2750 shelves were recommended in addition to approximately 3000 existing shelves for all storage areas.