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.
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:
Data Collection - Video shooting of all activities on the line.
Estimation & Data Analysis – PMTS technique estimation, work distribution, dashboard preparation, Muda & Muri analysis.
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.
Dashboard preparation for production planning as per demand.
Improvement & suggestions for fatigue reduction & making existing system better.
Production Planning Dashboard
Results & Conclusion
After doing analysis and evaluation following results were obtained –
Improved productivity by 65%.
Fatigue reduction by rotation of operators in between lines.
Overall Manpower Summary
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