Introduction
Launching a new vehicle model on an existing production line is both an engineering and operational challenge. It demands foresight, precision, and alignment across teams to ensure production starts smoothly, with no downtime, delays, or resource shortages. One of India’s prominent automotive manufacturers aimed to do exactly that: launch a new vehicle model without disturbing its current flow. For this, the company partnered with Production Modeling India (PMI) to conduct a Work Content Estimation Study using PMTS (Predetermined Motion Time System) techniques.
Client’s Challenge
• Conduct line balancing and resource planning to match the defined TACT time
• Validate assumptions during the Tool Try Out (TTO) and Production Prove Out (PPO) phases
• Avoid any production losses on the day of model integration
Line Balancing and Resource Planning for New Vehicle Model Launch Using PMTS Study
PMI’s Approach
PMI’s study began by reviewing the process sheet shared by the client. In the absence of real-time videos, the team developed elemental activity details based on engineering assumptions. Each process was assigned a standard time using PMTS.
Steps included:
- Developing station-wise work content sheets
- Identifying imbalances and recommending work redistribution to meet TACT
- Proactively suggesting buffer requirements and resource positioning
- Validating time data during TTO and PPO phases and refining it accordingly
Results & Impact
• Smooth launch with no production loss on Day 1 of new model integration
• Accurate estimation led to advance planning of manpower, tools, and fixtures
• Buffer planning ensured consistent flow across stations
• Strategic suggestions on monumental resource placement enhanced shop floor layout efficiency
Conclusion
PMI’s PMTS-led study empowered the client with clarity, control, and confidence for their new model launch. With every bolt, buffer, and body panel accounted for in advance, the plant didn’t just introduce a new vehicle—it elevated its production readiness.