Introduction
In the fast-paced world of automotive production, efficient process flow design is the key to sustaining productivity, controlling costs, and flexibility in responding to changes in production. The following case study was prepared on a process flow validation project carried out in one of the large automotive body shops that was planning to launch a new model (Model C) while existing models (A and B) continue to be produced. The central problem was to optimize the loop of pallet returns to accommodate multiple model variants without loss of production efficiency.
Client’s Challenge
The client’s body shop was preparing to integrate Model C into its existing production line. Each model type required a unique pallet configuration, which introduced complexity in managing the return and release of empty pallets. The proposed process aimed to:
- Release empty pallets in the correct sequence to match production demands.
- Minimize the need for manual “set-asides” of excess pallets, which were both space-consuming and labor-intensive.
Particularly, Station 5C-010's material handling robot was found to be a chronic bottleneck, having the highest utilization and lowest availability in Zone 1. The other bottlenecks were 5C-030 and 5C-200, suggesting an upstream clustering of performance limitations. Line efficiency was computed at 93.4%, while machine availability throughout zones varied between 97% and almost 100%. The analysis also validated that the proposed buffers between downtime areas were adequate under existing operational conditions, avoiding cascading delays and preserving continuity of flow.
Optimizing Smart Pallet Return System to Improve Body Shop Flexibility by 20% in Multi-Model Production
PMI’s Approach
PMI began by conducting a thorough analysis of the facility's operational data and verified the assumptions in the baseline process model. Attention was focused on the pallet return loop, where inefficiencies were suspected. Using flow simulations and real-time data observations, the team identified a critical bottleneck: excess pallets, particularly Model B, were frequently being manually set aside due to the lack of synchronization in the return process.
Findings and Recommendations
The evaluation revealed that the existing process flow was unable to efficiently handle fluctuations in pallet types. The return loop frequently became congested, forcing operators to manually remove and store surplus pallets—an approach that consumed both space and time.
PMI redesigned the pallet return loop to reduce the need for manual intervention. The revised process ensured a more synchronized and automated release of pallets, aligned closely with the production sequence.
Key outcomes included:
• A 25% reduction in the required buffer space would lead to immediate cost savings.
• The system could now accommodate up to 20% variation in the product mix without performance degradation.
• Manual set-asides were significantly reduced, improving workflow and reducing labor strain.
Optimizing Smart Pallet Return System to Improve Body Shop Flexibility by 20% in Multi-Model Production
Conclusion
Through strategic analysis and intelligent process redesign, PMI helped the client streamline pallet handling operations in a complex multi-model production environment. The revised process flow not only resolved existing inefficiencies but also introduced resilience to future production variability—an essential step toward operational excellence in automotive manufacturing.