Introduction
As one of India’s top tyre manufacturers expanded its footprint with a new production unit and introduced five new product types, it faced a crucial question: How can we ensure optimal performance from day one? With product diversity increasing and production complexity growing, the company needed to ensure every second on the shop floor was delivering value.
To tackle this, the client partnered with Production Modeling India (PMI) to carry out a focused Industrial Engineering (IE) study aimed at improving work balancing, streamlining manpower, and enhancing efficiency across the board.
Client's Challenge
• Balance workload and streamline manpower deployment across new product lines
• Identify process constraints along the value stream
• Adjust to cycle times ranging from 20 to 45 seconds, depending on product mix and demand.
PMTS-Based IE Study by PMI Sets Benchmark for Greenfield Tyre Manufacturing Unit - A Case Study
PMI’s Approach
PMI conducted a comprehensive study involving:
Capturing every relevant manual activity across the new unit.
Developing detailed process flows and schematic layouts.
Applying PMTS techniques to build elemental time details.
Creating charts to assess and optimize manpower distribution.
Delivering an Excel™-based planning tool for manpower and production resource planning under varying model mixes.
Key Outcomes
• Achieved process excellence in over 50 operations, guided by lean principles
• Improved manpower utilization across different model lines
• Performed line balancing to ensure stability across multiple cycle time scenarios
• Developed dynamic dashboards for future-ready production planning and real-time resource management
Conclusion
PMI’s IE study helped transform a greenfield setup into a lean and agile operation. By combining proven engineering techniques with real-time data and digital tools, the tyre manufacturer was able to lay the foundation for scalable, efficient, and cost-effective production—right from the start.