C-17 productivity takes off with Diamond Carousel Storage and Retrieval System (CS/RS)
When Boeing — the world’s leading aircraft manufacturer — won the contract to build the U.S. Airforce’s newest transport aircraft, the C-17 Globemaster III, they needed to lower production costs, meet fast-approaching deadlines and attain a 15% internal rate of return on investment within 5 years. To accomplish all this, they planned on increasing production from 12 to 15 aircraft per year without significantly adding employees.
Diamond Phoenix installed an integrated Carousel Storage and Retrieval System (CS/RS) to deliver parts faster and more accurately, be fully compatible with Boeing’s new Warehouse Management System software and include advanced features such as radio frequency scanning updates for simplified project tracking.
• Increased productivity by approximately five times
• Enhanced picking efficiency
• 56,000 square feet of storage space recovered
• Measurable improvements in quality control
• Surpassed all of Boeing’s goals
Boeing is the world’s leading aircraft manufacturer and sole producer of the U.S. Airforce’s new C-17 Globemaster III. Comprised of roughly 200,000 different parts, building the 179-foot C-17 would have required Boeing employees to push carts across nearly 250,000 square feet of assembly space.With the goal of delivering a 15% internal rate of return (IRR) in 5 years, Boeing had to find a cost-effective way to produce the C-17s. The company also planned to step up production from 12 to 15 aircraft per year without significantly increasing employees…but on such a compressed schedule the plan was impossible using their former system.
The Answer: Warehouse Modernization
Diamond Phoenix carefully analyzed Boeing’s storage and staging operations, then designed and installed an integrated Carousel Storage and Retrieval System (CS/RS).
Achieving and Exceeding Goals
Using twelve Diamond Phoenix horizontal carousels, the system stores 65% of warehouse inventory and transports parts via 400 available totes on two-level conveyors. Meeting Boeing’s aggressive production and inventory consolidation goals, the benefits of the Diamond system have been substantial.
• Picking efficiency improved five times over the manual system
• Dramatically increased accuracy
• Reduced storage space by 56,000 square feet with higher storage locations, and space requirements for smaller parts minimized
• Maximized worker comfort with Diamond Speed Station™ ergonomic workstations
• Substantially decreased chance of part damage
Headquartered in the United Kingdom, Diamond Phoenix has been providing innovative material handling solutions for companies like Boeing since 1979.
For more information on Diamond’s high performance material handling systems and capabilities, please call +44 (0)1908 592 354 or visit www.diamondphoenix.com.
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