A Comprehensive Case Study on Efficiency and Resource Optimization in Plywood Manufacturing Industry

PMI > Blog draft > Case Study > A Comprehensive Case Study on Efficiency and Resource Optimization in Plywood Manufacturing Industry

Executive Summary

In a changing market, innovation and operational excellence are crucial for growth. This case study illustrates how a top Indian plywood manufacturer improved efficiency with the help of Production Modeling India (PMI). With manpower utilization problems, operator fatigue, and idle capacity. The client joined hands with PMI to increase productivity, reduce waste, and achieve effective planning. PMI carried out a comprehensive study through PMTS, time studies, and production analysis in three stages: data collection, analysis, and implementation. Methods such as video observation and process validation identified activities that did not add value and streamlined workload allocation. The outcomes involved a 65% boost in productivity, elimination of fatigue through job rotation, and improved production visibility—enhancing the client's market position and preparedness for future expansion.

Client Overview

The client is a prominent plywood producer that produces high-quality products for various purposes.

Key Products: Flexible plywood and fire-resistant plywood

The client's manufacturing operations are diversified across multiple product lines and cover direct and indirect labor in multiple processes. While market demand was increasing, demands for increased productivity, more streamlined processes, and improved resource utilization became increasingly crucial to maintaining and growing their leadership position in the market.

Objectives of the Engagement

The primary objectives of the association were:

  • To analyze the operational work in detail with the help of PMTS (Predetermined Motion Time System), Time Study, and Production Study methods in scope areas.
  • To create work standard procedures and standards that would direct uniform and effective performance of tasks on the shop floor.
  • To calculate the correct cycle times for processes, review current manpower deployment, and measure the actual operating capacity of the plant.
  • To discover and remove Muda (waste) and non-value-added (NVA) activities and thus simplify operations and enhance throughput.
  • To utilize available resources in the most effective way possible, to enhance the efficient use of manpower and machinery
  • To make feasible suggestions for process enhancement, reduction of fatigue, and planning optimization based on findings from data analysis.

A Comprehensive Case Study on Efficiency and Resource Optimization in Plywood Manufacturing Industry

Download Case Study PDF

Objectives of the Engagement

Being a market leader in the plywood production industry, the client encountered various operational setbacks that restricted efficiency and hindered maximum utilization of resources. Such challenges necessitated the urgent need for systematic analysis and strategic intervention. The major challenges were:

  • Low Manpower Utilization
  • Operator Fatigue
  • Lack of Real-Time Production Planning Tools
  • Unknown True Capacity
  • Existence of Muda and Muri

These issues, if left unchecked, would have resulted in lost opportunities in terms of scale and profitability. The client thus commissioned PMI to identify and eliminate such systemic problems through a systematic and data-driven methodology.

Challenges Faced by Client

Being a market leader in the plywood production industry, the client encountered various operational setbacks that restricted efficiency and hindered maximum utilization of resources. Such challenges necessitated the urgent need for systematic analysis and strategic intervention. The major challenges were:

Purges that occurred frequently during regular purge cycles interrupted flow and introduced delays in the sealer area.

These maintenance operations were asynchronous, impacting the overall system timing and productivity.

Part removal for quality inspection caused periodic flow disruption.

Downtime in one zone had cascading effects on adjacent zones due to inadequate isolation or buffering, complicating production stability.

PMI’s Three-Stage Approach

To address the client's challenges and achieve the defined objectives, Production Modeling India (PMI) adopted a structured, three-stage methodology.

Data Collection

The first stage involved comprehensive data gathering to build a solid foundation for analysis.
• Video Documentation of Activity
• Process Understanding Through Collaboration
This extensive documentation enabled PMI to record real-time work behavior, determine patterns, and discern latent inefficiencies that could be missed in conventional walkthroughs.

Estimation and Data Analysis

The second stage involved the use of industrial engineering methods to mine the data for insights.
• PMTS-Based Elemental Breakdown
• Work Distribution and VA–NVA Analysis
• Manpower Optimization and Capacity Calculation
• Dashboard Preparation for Planning

Results and Recommendations

In the last stage, actionable recommendations were created and presented to the client to be executed.
• Fatigue Reduction Measures
• Productivity Improvement Recommendations
• System Enhancement Proposals
This three-level approach guaranteed that improvements were not only recognized but w

Key Results and Outcomes

The organized interaction and joint implementation between PMI and the client yielded revolutionary outcomes in various operational areas. The results were as follows:
• Productivity Improvement of 65%
• Improved Manpower Utilization
• Fatigue Reduction Through Job Rotation
• Visibility into True Plant Capacity
• Implementation of Planning Dashboards
• Elimination of NVA Activities Identification

Production Planning Dashboard
Overall Manpower Summary

Together, the results enabled the client to not only improve today's operations but also create a strong foundation for sustainable improvement and scalable growth.

A Comprehensive Case Study on Efficiency and Resource Optimization in Plywood Manufacturing Industry

Download Case Study PDF

Team Involvement

Success in this interaction was fueled through seamless coordination of PMI experts with the in-house stakeholders from the client's organization.
PMI Team
• 1 Project Manager
• 2 Industrial Engineers
Client Team
• 2 Project Coordinators

Conclusion

In conclusion, this case study showcases how data-driven techniques and coordination with Production Modeling India (PMI) assisted a major plywood industry leader in making significant operational gains. Through work measurement, resource utilization, and waste reduction with PMTS and time studies, the client addressed core issues such as low manpower usage, operator fatigue, and inefficient planning. The project uncovered non-value-added activities, facilitated improved workload allocation, and brought real-time dashboards to production planning. Because of this, the company gained a 65% productivity improvement, eliminated fatigue via operator rotation, and gained visibility into the plant's actual capacity. These changes not only improved day-to-day operations but also set the client up for long-term growth and dominance in a competitive industry.

Related Case Studies

Streamlining Capacity and Resources Optimization in Agriculture Machinery/Equipment Manufacturing Industry

Indirect Area Study in Tyre Manufacturing Industry

Transforming Electrical Soft Ferrite Core Manufacturing Industry through IE Study

Productivity Improvement in Agricultural Equipment Manufacturing Industry

Stopwatch Time Study Enhances Efficiency and Production for a Prominent Bike Manufacturer in India

Optimizing Aeronautical Operations Efficiency with Time and Motion Study

    Download Our Company Brochure