Evaluating new equipment and processes
XOM evaluated new equipment installation and process change for the Films Division with ProModel, to determine the impact of these changes on the rest of their operations. ProModel identified numerous unforeseen constraints involving automated guided vehicle operations. Once equipment was purchased and processes changed per ProModel recommendations, the plant was enabled to produce 40% over previous expectations. Millions of dollars of benefit were realized with this ProModel solution.

Evaluating new equipment and processes
ProModel provided modeling, manufacturing process analysis and recommendations needed for GM to make critical launch decisions that saved millions of dollars. GM and a tier-one supplier were uncertain whether a new manufacturing process design for a critical stage of the new vehicle would produce the desired jobs per hour. ProModel discovered an unexpected constraint, which would have caused a 30% shortfall. ProModel recommendations were implemented and the launch was saved. The supplier chose to integrate ProModel for ongoing process improvements.

Capacity analysis and improvement
Carrier Corporation, a division of United Technologies, used ProModel to accurately model their refrigeration equipment paint line. They found that more than $800K of planned throughput improvement projects would have little or NO impact on actual throughput. Instead they proved that, by installing a new paint oven, they could adequately improve throughput. This caused an annual benefit of $370K, and resulted in overall savings to Carrier of more than US $1 million.

Capacity analysis and improvement
Modeling the entire laser plant helped Cymer ramp up production by 400% in one year, which allowed a revenue increase of over $180 million. ProModel was used to optimize new layout design, evaluate process changes, find and exploit constraints, schedule personnel, control WIP and investigate the impact of new techniques (i.e.: switching from a “push” to a “pull” system, evaluating just-in-time material flow, etc.).

Inventory Reduction
Fiat found that ProModel enabled them to accurately model their process, reduce work-in-process inventory by 48%, reduce lead times, and reduce space requirements. From dozens of possible improvement initiatives, ProModel enabled them to identify specific plant scheduling changes and process improvements resulting in a large ROI and over US $1 million savings.

Capacity analysis and improvement
ProModel accurately modeled Wright’s complex bacon production processes, helping them make valuable recommendations for new equipment, changes in process, and improved scheduling of personnel. This solution enabled Wright Brand Foods to double production capacity and save more than $10 million.

Continuous Improvement
Eastman Chemicals uses ProModel to continuously analyze and evaluate manufacturing improvement opportunities, to determine whether new ideas will be valuable before risking implementation. Countless dollars in savings have been realized though improved cycle times, new equipment evaluations, throughput improvements, railcar loading improvements, optimized staffing and material handling designs.

    High Tech     Manufacturer

Reduce costs
This high tech manufacturer with over $2 billion per year revenue relied on custom solutions from ProModel to avoid unnecessary capital investments, to make significant cost reductions in labor input per unit, to shorten production cycle times and to improve quality. An example of how ProModel has helped was to determine that no new downstream capital equipment was required if the upstream throughput was increased by 30%. This manufacturer would have invested millions of dollars in the new equipment if they did not have the predictive technology from ProModel that allowed them to safely decide on their best business decision.

Evaluating alternative manufacturing techniques (lean)
Boeing used the predictive technology from ProModel to successfully implement lean manufacturing and dramatically reduce manufacturing costs. A counter-intuitive process change was identified that reduced work-in-process inventory by 1/3 and improved delivery performance in a complex manufacturing process with over 1 million separate parts. The area supervisor had suspected this improvement would work, but until a custom ProModel solution was built, management had little faith to make the change. Our technology is all about risk-free decision-making in the safety of world-class software.

B: Success Stories for Logistics

Transportation system design
Over the last 10 years in a variety of applications, ProModel has helped DuPont save millions of dollars. One such application involves the optimal design of their rail fleet, modeling the variability inherent in chemicals production, tank car availability, transportation times, loading and unloading times and customer demand. The first application only took 2 weeks and saved $500,000.

Transportation system design
Volkswagen saved more than US$20 million per year with a custom solution for their plant-to-distribution center-to-dealer delivery system. Improvements included changing distribution center locations and subsequently replacing some expensive truck routings with cheaper rail or sea routes.

Supply chain optimization
ProModel technology has been used to model and improve the complex supply chain for rocket engines and flight hardware between Thiokol's western US facility and Cape Kennedy in Florida. Special logistics are required to handle all the rocket parts, including reusable motor segments in expensive rail cars. Our solution allows them to use less rail cars, thus saving time and improving NASA flight schedule reliability. Savings are estimated to be more than US$1 million.

Event logistics and planning
The 2002 Winter Olympics were one of the most complex logistics challenges EVER. ProModel products and services were used to design security systems and bus transportation for most of the venues. The predictive technology enabled the Salt Lake Organizing Committee to model and test various scenarios related to security operations, weather, and transportation system design.

Evaluating new equipment and processes
Delta used ProModel to evaluate new equipment for transporting planes. They evaluated an investment in new tugs that could be cross-utilized, and developed an optimum solution that saved Delta millions of dollars.

Emergency prepardness
The FAA Aviation Safety Hotline takes calls from people having knowledge of FAA regulation violations and disasters. ProModel developed a custom model of their phone system and expected variation of incoming calls based on various past disasters. The solution was used to design and evaluate new technology and staffing, thus improving customer service to the public at lower cost.

Kennedy Airport

Airport baggage handling and security
ProModel evaluated new technology and system design for screening of checked baggage at Kennedy Airport. The objective was to screen bags without excessive passenger wait times. A complete model was developed that evaluated passenger and baggage movement from curbside to aircraft. Read more on aviation security.