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Associated Hygienic Products. September 21, 2006. The Market. Retail disposable diaper/training pants/youth pants $4.2 billion in the U. S. Declining category sales Declining birthrate Enhanced product performance 20% branded product (Pampers, Huggies) 80% proprietary branded product.

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Associated Hygienic Products

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Associated Hygienic Products

September 21, 2006


The Market

Retail disposable diaper/training pants/youth pants

  • $4.2 billion in the U. S.

    • Declining category sales

      • Declining birthrate

      • Enhanced product performance

    • 20% branded product (Pampers, Huggies)

    • 80% proprietary branded product


The Company

  • Wholly owned subsidiary of Disposable Soft Goods International (DSG)

  • Second largest U. S. corporate brand manufacturer

  • 2002 sales: in excess of $160 million

  • U. S. Headquarters: Duluth, GA

  • 2 U. S. manufacturing plants

    • Vancouver, WA

    • Marion, OH


The Challenge

  • Marion, OH

    • Current plant old, expanded over the years

    • Inefficient layout


Current Plant


The Challenge

  • Marion, OH

    • Current plant old, expanded over the years

    • Inefficient layout

  • New plant:

    • Under construction

    • First machine early next year

    • Production area has been decided

    • Seeking a second opinion / analysis / new ideas for the warehouse

      • Layout

      • Equipment

      • Etc.


New Plant


New Plant


The Data


Finished Goods Dimensions


Finished Goods Inventory Spots


Boxes Min/Max


Standard Production Output


Raw Material Receipts


Finished Goods Production


Finished Goods Production


Raw Material Dimensions


Raw Material Flow to Production


Raw Material Flow to Production


Other Data

  • Yet to be received

  • Bills of Material

    • Lists all raw materials for a production run

    • One per run per SKU

  • Sales orders


Miscellaneous

  • Your mission, should you choose to accept it…

    • Mathematical model of the warehouse

      • Recommended layout

      • Recommended equipment

      • Financial justification for equipment investment


Miscellaneous

p_viehweg@bellsouth.net


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