This case study presents the journey of transformation of India's top and the world's largest tractor producer, known for its high quality and extensive product line. With a rich tradition of excellence, the company wanted to further improve operational efficiency, maximize manpower utilization, and synchronize production with changing market needs. As new models of tractors were launched, it was essential to reassess assembly operations and resource allocation. Collaborating with PMI, the company embarked on a systematic process of analyzing, optimizing, and streamlining operations using cutting-edge methods such as PMTS and DFA-based analysis, establishing a productivity benchmark and opening the door to long-term manufacturing excellence.
• Experienced high manpower fatigue levels, affecting productivity and employee morale. • Low manpower utilization, resulting in ineffective resource allocation across assembly lines. • Required accurate production planning tools to match fluctuating market demand. • Lacked visibility into the true capacity potential of the plant and workstations. • Structured Muda (waste) and Muri (overburden) analysis is needed to identify process inefficiencies. • The existing workstation layout was not optimized for a multi-model assembly line setup. • Sought actionable insights to improve work distribution and reduce non-value-added (NVA) tasks.
The major objectives of the simulation exercise were to:
To meet the client's needs in a high-stakes manufacturing setting, PMI took a disciplined and team-oriented approach. With extensive experience optimizing intricate production systems—specifically within markets such as renewable energy and heavy equipment manufacturing—PMI provided a harmonious blend of technical accuracy and operational expertise.
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.
To address the client’s complex production challenges, PMI implemented a structured six-stage approach that combined static analysis with advanced simulation modeling.
PMI started by ensuring all data provided by the clients, i.e., robotic timings, cycle times, and machine settings, were verified. This served to provide a theoretical baseline for system performance, utilization, and output capacity.
The production logic, interdependencies, and downtime behaviors were studied by the team to conceptualize an adaptable and flexible model structure. This process ensured all the important parameters and future change patterns were considered.
PMI created an elaborate computer model of the production system with simulation software. The model was thoroughly validated and cross-checked against static analysis results to ensure correctness.
Various scenarios were simulated with different buffer sizes, machine availability, and maintenance cycles to observe their effect on throughput and efficiency.
Important observations were recorded and possible areas of improvement identified.
Throughout the project, PMI collaborated with client stakeholders in close coordination to maintain alignment and transparency in modeling and recommendations.
To meet the client's needs in a high-stakes manufacturing setting, PMI took a disciplined and team-oriented approach. With extensive experience optimizing intricate production systems—specifically within markets such as renewable energy and heavy equipment manufacturing—PMI provided a harmonious blend of technical accuracy and operational expertise.
PMI organized the engagement into three directed stages to guarantee extensive diagnosis, solution creation, and quantifiable results:
Phase 1: Data Collection
Captured layout and processed information through plant walkthroughs, DFA drawings, and team meetings.
Phase 2: Estimation & Data Analysis
Applied PMTS methodologies to estimate work content, making it possible to perform detailed manpower analysis, work allocation, and dashboard generation.
Phase 3: Results & Implementation
Provided an optimized, balanced multi-model assembly plan with suggestions for fatigue minimization and resource planning.
PMI Team: 1 Project Manager and 2 Engineers managed the technical execution.
Client Team: 2 Project Coordinators maintained alignment with the internal process team and ensured data accuracy.
This systematic, team-based methodology served to reveal bottlenecks, decrease inefficiencies, and lay the groundwork for lean, scalable manufacturing systems.
PMI started by closely scrutinizing the client's current assembly configuration. This involved in-depth walkthroughs of the shop floor, analysis of existing layouts, and examination of DFA (Design for Assembly) drawings to determine the sequence of operations. Close interaction with the client's process team facilitated correct interpretation of workflows and synergy on assembly logic. These observations formed the basis for the identification of inefficiencies and preparation of correct elemental breakdowns. By basing the study on real-time observations and confirmed data, PMI established a real-world foundation for follow-on analysis and optimization work.
Applying the PMTS technique, PMI calculated the exact work content of every assembly activity. Elemental information was developed for every operation and confirmed in cooperation with the client's process engineers. This made it possible to identify Value-Added (VA) and Non-Value-Added (NVA) activities accurately, which served as the foundation for the optimization of manpower distribution.
Work allocation was examined between stations with the objective of balancing workload, determining bottlenecks, and enhancing overall flow. PMI also incorporated these results into SAP to produce production planning dashboards providing real-time visibility into takt-based resource needs and actual capacity utilization of the plant.
• Accomplished line balancing for a 2.56-minute takt time across a multi-model assembly line.
• Determined and resolved bottleneck stations, enhancing overall flow efficiency.
• Created optimized workstations within the bounds of the current plant layout.
• Estimated manpower requirements at 85% utilization, enhancing labor efficiency.
• Designed dashboards connected to SAP for precise, demand-based production planning.
• Designed in-depth elemental breakdowns with PMTS, checked for the process team.
• Suggested changes for minimizing operator fatigue and maximizing ergonomics.
• Facilitated understandable insights into the plant's actual capacity for future planning and scaling.
The joint effort between PMI and the customer resulted in substantial, quantifiable gains throughout operations. By reaching 85% manpower utilization, the company maximized labor efficiency without overloading workers—finding the optimal balance between productivity and well-being. The removal of bottlenecks and streamlining of assembly flow, as well as takt-based line balancing, facilitated smoother multi-model production with minimal disruption.
Production planning dashboards enhanced real-time decision-making, aligning output with demand fluctuations. Additionally, the ergonomic improvements contributed to reduced fatigue and better workplace morale. Overall, PMI’s intervention empowered the client to unlock hidden capacity, drive leaner operations, and lay the foundation for sustained manufacturing excellence.
This case study exemplifies how a structured, data-driven approach can drive transformative results in complex manufacturing environments. Through the use of PMTS, DFA drawings, and advanced line balancing methodologies, PMI assisted the world's largest tractor manufacturer to improve efficiency, optimize resources, and enhance labor utilization. In addition to yielding instant shop-floor benefits—such as smoother line flow and lower fatigue—the project initiated scalable systems for sustained growth. PMI’s expertise in industrial engineering and collaborative execution enabled the client to uncover their plant’s true potential, reinforcing their position as a global leader in tractor manufacturing committed to continuous improvement and operational excellence.
