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

August 22, 2023

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


mbawankar |

Discover how a leading plywood manufacturer excelled by diversifying its product line, including innovative flexible plywood and fire-retardant solutions. A strategic approach hinged on methodologies like PMTS, Time Study, and Production Study drove operational efficiency. Waste reduction, resource optimization, and dashboard-integrated planning led to increased productivity. Insights from waste analysis refined processes iteratively, unveiling the plant's true capacity and addressing low manpower utilization. A story of excellence and innovation, cementing the company as a plywood industry leader.

Key Points

  • Work Content Measurement using PMTS technique, Time Study or Production Study of in-scope areas.
  • Work Standard Development
  • Cycle Time, Manpower & Capacity Calculation
  • Eliminating Waste and Non-Value-Added Activities to increase productivity.
  • Improving the effective Utilization or Optimization of resources
  • Improvement and Suggestions for making existing system better.

Client's Challenge

  • Reduction in manpower fatigue.
  • Dashboards for production planning as per demand.
  • Muda & Muri analysis for further improvement.
  • Identify true potential capacity of plant.
  • Low manpower utilization.

PMI's Approach

The study was organized in a 3-stage process:

  1. Data Collection - Video shooting of all activities on the line.
  2. Estimation & Data Analysis – PMTS technique estimation, work distribution, dashboard preparation, Muda & Muri analysis.
  3. Results and Conclusion – Dashboards for future planning, fatigue reduction, improved productivity, improved manpower utilization, identification of NVA work content.

Involvement of Associates

  • PMI – 1 Project Manager, 2 Engineers.
  • Client – 2 Project Co-ordinators.

Data Collection:

  • Video recording of the activities carried in Direct and Indirect areas of the in-scope areas.
  • Interaction with client to understand process from videos.

Data Analysis:

  • Preparation of elemental details using PMTS technique & validation by client.
  • Analysis (Work distribution/VA-NVA identification) for manpower calculation, optimum manpower utilization & identifying capacity.
  • Dashboard preparation for production planning as per demand.
  • Improvement & suggestions for fatigue reduction & making existing system better.
Production Planning Dashboard

Production Planning Dashboard

Results & Conclusion

After doing analysis and evaluation following results were obtained –

  1. Improved productivity by 65%.
  2. Fatigue reduction by rotation of operators in between lines.
Overall Manpower Summary

Overall Manpower Summary

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