Assembly of the engine isn't simply a matter of torque and timing—it's rhythm. A symphony of well-coordinated stations, tools, and manpower working together in harmonious synchrony. But when the stage itself, the layout, is preventing the performance? That's the problem that top DG Set engine maker wanted to solve when it relocated operations to a new facility and redesigned its plant layout.
The challenge was not only to insert the current process into a new space, but to reimagine how the plant operated, simplifying movement, leveling the line, and maximizing every minute and every meter. With Production Modeling India (PMI) as the industrial engineering partner, the makeover was initiated.
There were three distinct goals for the project:
This was not a mere relocation, it was a chance to future-proof the plant, boost productivity, and improve aesthetics and safety simultaneously.
PMI’s team started with a thorough walkthrough of the existing facility to understand the real-time process flow, bottlenecks, and operational pain points. Key activities included:
Studying current layouts and productivity reports
Identifying space usage inefficiencies
Conducting elemental work measurement for each assembly activity using PMTS
Three detailed layout options were created and compared on multiple parameters:
The effect of the redesign was not only aesthetic—it was quantifiable. The most important metrics compared between the current and proposed systems demonstrated:
Existing:
Under-utilized Manpower
Production at 6.7 min Takt
Uneven Line Balancing
Proposed:
Increased Manpower Utilization
Production at 4.01 min Takt
Stations and Activities are merged for Line Balancing
PMI also offered important improvement recommendations to further enhance performance:
Powered conveyors for decreased dependency and efficiency of movement
Oven length enlargement to increase throughput
Coolant and water filling automation for eliminating additional cycle time
What began as a change in location became a total re-examination of the way that the plant operated. By using smart layout planning, accurate work measurement, and data-driven decision-making, PMI enabled the client to gain substantial improvements in efficiency, safety, and scalability. Ultimately, it wasn't merely an assembly line that was reoriented, it was the very pace of production.
