Introduction
In high-precision manufacturing, mold shops serve as the foundation for consistent product quality and repeatable processes. A leading manufacturing client, operating one such mold shop, was struggling to identify inefficiencies in manpower and machine utilization. While production continued steadily, there were signs that the true potential of the plant was not being realized. To uncover hidden inefficiencies and enhance productivity, the client engaged Production Modeling India (PMI) to carry out a comprehensive Work Content Estimation using MODAPTS techniques.
Client’s Challenge
• Lack of standardized time data for molding activities
• Unbalanced workload between man and machine resources
• Unclear visibility into the plant’s actual capacity
• No formal work content documentation for process improvement initiatives
Production Analysis in Car Manufacturing Industry - Case Study
PMI’s Approach
PMI initiated the project with detailed video documentation of all molding operations on the shop floor. Using this footage, each activity was broken down into elemental details and evaluated using the MODAPTS (Modular Arrangement of Predetermined Time Standards) method to calculate standard times.
The study involved:
- Mapping each task with time-indexed motion elements
- Preparing man-machine charts to visualize utilization gaps
- Conducting multi-manning and multi-machining studies to evaluate the effect of workforce flexibility
- Suggesting layout and method improvements to reduce fatigue and non-value-added time
Findings & Results
• Productivity improved by 35% through the implementation of multi-manning and better task distribution.
• With layout and method changes, an additional 24% productivity gain was projected—bringing the total improvement potential to 59%.
• Manpower requirements were reduced by 30%, helping free up labor for other critical operations.
• The plant’s actual capacity was established, enabling the client to better align staffing with production goals.
Conclusion
Through structured analysis and motion-based time study, PMI helped the client redefine productivity benchmarks for their mold shop. What started as a time study evolved into a transformational exercise in process optimization, unlocking performance gains and enabling smarter planning for the future.