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Fabrication Division Logistics Process Modernization – UA14-RRAD – Phase III


Red River Army Depot – Texarkana, TX

Research Team:

Manuel Rossetti, P.E., Ph.D. and Harry Pierson, Ph.D.

Universities Involved:

Department of Industrial Engineering – University of Arkansas

Start Date:

August 2014

End Date:

August 2016


The Red River Army Depot has identified their Fabrication Division as a candidate for logistics improvement and re-engineering activities that can improve work planning, material supply, and production capabilities. The Fab Division is the area where production orders and maintenance work orders are fulfilled. It is a high‐mix, low-volume job shop. Daily operation suffers from a number of inefficiencies including the material ordering process, scheduling, and the fulfillment of orders. There are several issues with the layouts and functions of the buildings. Consequently, one of RRAD’s main challenges is delivering parts to customers by the promised due date. At this point, it is virtually impossible to give an accurate delivery date due to several aspects of the order fulfillment process creating a long and unpredictable lead time.

The objective of this research project was to investigate re‐engineering and process improvement activities that can leverage alignment with ERP practices in order to improve work planning, supply, and production capabilities within the RRAD Fabrications Division. In addition the project should address the following two questions:

  • What industry best practices should be recommended?
  • Do automated machine tools, flexible automation, alternative processing methods, layouts, work flow, or work cells offer advantages for this low volume/high product mix environment?

The project methodology involved 1) investigating Fab Division processes, 2) identifying opportunities for improvement, 3) collecting/cleansing/organizing data, 4) analyzing data.

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