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