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"Improving manufacturing and distribution operations since 1958
More than 800 projects completed throughout North America, Europe, and Asia"

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Case Studies


Business: Engine Re-Manufacturing

Nature of Work or Scope and Results

This project was performed for the major engine re-manufacturing division of a large corporation. At any one time, the division houses more than 50,000 core engines and component engine parts for thousands more. This is a relatively complex business that works with a "bill of yield" rather than a typical bill of materials for its products. The company never knows what will be salvageable from a core engine received (from stock or from dealers), thus the requirement for a bill of yield and a bill of new parts to be manufactured and new parts to be purchased. The "yard stick of success" in this business is to manage inventories down and quality up so that the ratio of purchased or newly machined parts is low compared to the usage of salvageable parts.

SCG was engaged to study the operations, determine whether cellular manufacturing and single piece flow were appropriate for portions of the operation, and develop the complete layout plans for a new consolidated facility. The new facility will house operations that currently reside in four facilities.

Several alternative assembly line/cell operations were developed. Single piece flow layout alternatives were developed for cylinder head machining, camshaft machining, and core block machining. Cellular layouts for cylinder head machining for both new and old engines will be difficult to achieve and will be phased in over time (after the consolidation). This area has the widest mix of old and totally new heads and favors traditional batch approaches. Small batch, single piece flow in the other areas mentioned was relatively easy to achieve.

The layouts were completed and the operations were successfully consolidated into the new facility.


















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