Background
SCAFCO's 110,000 sq ft roll-forming plant was running from a layout drawing that no longer matched the floor. I rebuilt the layout from field measurements, then used it with production-usage data to reorganize steel-coil storage and standardize packaging lumber.
Facility Remapping
Equipment and storage had moved since the AutoCAD layout was last updated. I measured the facility and rebuilt the drawing to show the actual locations of production equipment, coil bays, storage areas, operator access paths and working space around the machines. That drawing became the baseline for the storage work below.
Steel Coil Storage
Coils move from storage to the roll-forming lines by overhead crane. Coils of the same dimensions and gauge were scattered across the bays, which made them harder for crane operators to find, and some frequently used coils sat far from the lines that consumed them.
Using coil usage data and the updated drawing, I designed a consolidated layout: coils grouped by dimensions and gauge, the most-used groups placed nearest the lines that use them, and access kept clear for crane operators and production staff. The new arrangement made coils easier to locate and reduced crane travel between storage and production.
Packaging Lumber
Finished studs are packaged with lumber cut to lengths that depend on the product. The plant stocked more lengths than it needed, which meant excess inventory, repeated cutting, extra handling and offcut waste.
I sampled and measured the lumber used across production and ran a frequency analysis in Excel. Where a short length could be cut evenly from a longer one, such as two 12-inch pieces from one 24-inch piece, the short length did not need its own stock. Usage frequency and length divisibility together gave a smaller set of standard lengths that covered every packaging requirement, and the most-used lengths were moved closer to the machines that use them.
Result
Production facility remapped in AutoCAD.
Reduction in packaging lumber inventory.
The consolidated coil layout cut crane travel time between storage and the roll-forming lines and improved operator access.
