In the constantly changing world of flexible packaging, precision and efficiency are the top priority. One of the world's top manufacturers of Bi-axially Oriented Polypropylene (BOPP) films understood they had to maximize their operations in order to stay competitive and sustainable. The customer is known as a specialty packaging solutions provider with ultrahigh barrier films, coatings, and lamination under its umbrella, and serves domestic and overseas markets. Its films have applications in a wide array of products, from foods and labels to industrial and non-food FMCG.
In order to overcome manpower utilization, layout inefficiency, and productivity deficiencies problems, the client collaborated with Production Modeling India (PMI) to conduct a detailed work content measurement and process improvement study utilizing PMTS (Predetermined Motion Time System) techniques.
The engagement was arranged around the following fundamental objectives:
Despite working in a high-capacity production setup, the client encountered various operation issues:
• Manpower under-utilization, with an average utilization level as low as 49%.
• Inefficient and manual material flow, resulting in process delays and operator fatigue.
• Lack of real-time dashboards, limiting the ability to plan production as per fluctuating demand.
• An inefficient layout causes unnecessary movement and delays in task execution.
In order to evaluate the existing operations the client needed a structured approach. They also were needed to identify the areas for improvement and implement the appropriate changes to gain quantifiable results.
PMI adopted a three-phase methodology to deliver actionable insights and tangible improvements:
The project started with an extensive video recording of every shop floor operation, recording live activity in real-time across different production lines. It involved operator activities, handling of equipment, material transport, and coordination points within processes. The rich visual information formed the basis for time and motion analysis.
By applying the MODAPTS (Modular Arrangement of Predetermined Time Standards) method, PMI carried out comprehensive work content estimation for every task. These measurements of time were utilized to:
• Create a balanced operator workload distribution.
• Create visual dashboards to support production planning and monitor manpower performance.
• Create a harmonized material flow to reduce travel distance and idle time.
• Suggest changes in the layout for lean operations and better ergonomics.
The analysis contributed to identifying differences in value-added and non-value-added operations or tasks to understand and identify which tasks are consuming more time and how work can be streamlined.
The implementation of PMI’s recommendations led to impressive improvements:
• Productivity increased by 45%, achieved through optimized task sequencing and layout refinement.
• Manpower requirement reduced by 31%, without compromising output or quality.
• Manpower utilization was enhanced considerably, improving from a mean of 49% to 73%, indicating improved balancing of workload and decreased idle time.
• Future planning dashboards were created to synchronize production scheduling with real demand and line performance.
The redesigned layout and coordinated material flow lessened operator fatigue and improved ergonomics, which further contributed to greater operational stability and manpower efficiency.
This case study illustrates the power of scientific work measurement when integrated with process redesign and data-driven planning to bring transformative outcomes in a manufacturing setting. Through the application of PMTS methods, PMI enabled the client to reveal deep-seated inefficiencies, redesign processes for maximum flow, and substantially improve overall productivity.
In a speedy, quality, and cost-driven competitive industry, the customer is now better positioned to respond to changing customer needs with a more responsive, sustainable, and efficient operation. The success of this project is a strong case in point of how new industrial engineering can unleash value and drive continuous improvement for the manufacturing industry.
